Disposable absorbent insert for two-piece wearable absorbent article

ABSTRACT

A wearable absorbent article having features for the containment and absorption of bodily exudates. The article may comprise an outer cover and an absorbent insert. The outer cover may be formed of durable or semi-durable materials and be launderable. The insert may be disposable. The insert may have containment and absorption features that prevent soiling of the outer cover by the wearer&#39;s exudates, so that the outer cover may be reused after an exudation event and change of inserts. The insert and/or the outer cover may have features to enhance containment, absorption, economy of materials and/or fit that make them asymmetric about their respective lateral axes, and may have features that direct a user to install the insert and/or the outer cover with correct front-rear orientation relative the wearer. Articles of commerce including packages of outer covers and/or inserts in varying combinations of numbers and features are also described.

CROSS REFERENCE TO RELATED APPLICATION

To the extent allowable, this application claims the benefit of thefiling date of U.S. Provisional Application No. 61/144,866, filed Jan.15, 2009, the substance of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to the field of diapers andother wearable absorbent articles having features for the containmentand absorption of bodily exudates, and more particularly, to sucharticles having disposable absorbent inserts and reusable outer covers.

BACKGROUND OF THE INVENTION

It is likely that reusable diapers made of cloth have been in use sincethe invention of cloth. Reusable cloth diapers, however, presentdifficulties relating to sanitation needs, in handling, laundering andeffectively sanitizing soiled diapers for re-use. Reusable cloth diapersalso may be relatively unreliable with respect to containing bodilyexudates (i.e., they may tend to leak). Because a wet cloth diaper maybe in direct contact with the skin, unless wetness is quickly detectedand the wet diaper removed, it may promote over-hydration of thewearer's skin, which makes the skin vulnerable to diaper rash.

The introduction of disposable diapers in relatively recent times hasmitigated these disadvantages for many. Generally, upon removal from awearer, a soiled disposable diaper need not be emptied, laundered orhandled to any significant extent, but rather, may be discarded as is.Any soiled areas of the wearer's body may then be cleaned, and a cleannew disposable diaper may be placed on the wearer as necessary. Manycurrent disposable diapers have structures that make them relativelymore effective at containing exudates than traditional cloth diapers.Many have structures and materials that make them relatively moreeffective at conveying and storing liquid exudates away from thewearer's skin. Some have features that enable them to “breathe”, therebyreducing humidity inside the diaper, and some even include skin carecompositions that are transferred to the skin when the diaper is worn.Such features may reduce the likelihood and/or extent of skinover-hydration and otherwise promote or help maintain skin health.

For economic reasons, currently most disposable diapers are made ofsubstantial proportions of materials derived from petroleum, such aspolypropylene and/or polyethylene. These materials often appear in theform of spun fibers forming cloth-like nonwoven web materials, oralternatively or in addition, films.

In recent years concerns have arisen concerning the “environmentalfootprint” of human activities of all kinds. The manufacture and use ofdiapers is no exception, particularly in view of the growing humanpopulation, i.e., the growing number of babies. One view seems to bethat use of disposable diapers is detrimental to the environment becausethe materials of which they are typically made may be derived fromnon-renewable resources and require substantial amounts of energy intheir manufacture. Additionally, because disposable diapers typicallyare not re-used or recycled, their use may be deemed by some to beunsatisfactorily taxing upon disposal facilities such as landfills. Ifthe alternative is reusable cloth diapers, however, another view seemsto be that the increased use of energy (e.g., for operating equipment,heating laundry water, and treating wastewater) and chemicals (e.g.,detergents and water treatment agents), necessary for laundering soileddiapers at the rate they are typically used, and treating the associatedwastewater, present their own set of stresses on the environment. As maybe appreciated, analysis concerning which alternative is more“environmentally friendly” is complicated, and undisputed conclusionseither way do not yet appear to exist.

Regardless of which alternative one may believe is more environmentallyfriendly, however, it appears that in developed nations, today'sdisposable diapers are generally favored over reusable cloth diapersamong caregivers of babies and young children. This is probablyattributable to the advantages of reducing or eliminating theunpleasantness, sanitary concerns, and extra work and/or expenseassociated with handling and laundering soiled reusable cloth diapers,better containment of exudates, and effectiveness at promoting and/orhelping maintain skin health.

Manufacture of wholly disposable diapers is generally considered acapital-intensive business. This is a consequence of the complexmachinery required to produce product from incoming material streams ateconomically-feasible production rates, which often exceed 450 or morearticles per manufacturing line, per minute. Any innovation which hasthe potential to simplify the process or the equipment required, orreduce material costs, has the corresponding potential to reduceper-article costs for the manufacturer and the consumer.

Several designs of diapers that include a reusable cloth outer cover andeither a reusable or a disposable absorbent insert have beenmanufactured and marketed. However, for the user, these designs havestill presented at least some of the disadvantages of traditional clothdiapers, while not providing some of the advantages available fromcurrent disposable diaper designs.

In view of the concerns set forth above, it would be advantageous if awearable absorbent article were available that provides advantagesafforded by both disposable and reusable diapers, while reducing therespective disadvantages of these alternatives. It also would beadvantageous if a construction were provided that could simplifymanufacturing processes and/or reduce costs.

BRIEF DESCRIPTION OF TILE DRAWINGS

FIG. 1 is a perspective view of a wearable absorbent article as it mightappear being worn by a wearer about the lower torso;

FIG. 2A is a plan view of an outer cover opened and laid flat, outersurface facing the viewer;

FIG. 2B is a plan view of an outer cover opened and laid flat, innersurface facing the viewer;

FIG. 2C is a plan view of an outer cover opened and laid flat, innersurface facing the viewer;

FIG. 2D is a plan view of an outer cover opened and laid flat, innersurface facing the viewer;

FIG. 2E is a plan view of an outer cover opened and laid flat, innersurface facing the viewer;

FIG. 2F is a plan view of an insert opened and laid flat, outer (garmentfacing) surface facing the viewer;

FIG. 2G is a plan view of an outer cover opened and laid flat, innersurface facing the viewer;

FIG. 2H is a plan view of an insert opened and laid flat, outer(garment-facing) surface facing the viewer;

FIG. 2I is a plan view of an outer cover opened and laid flat, innersurface facing the viewer;

FIG. 2J is a plan view of an insert opened and laid flat, outer(garment-facing) surface facing the viewer;

FIG. 2K is a plan view of an outer cover opened and laid flat, innersurface facing the viewer;

FIG. 2L is a plan view of an insert opened and laid flat, outer(garment-facing) surface facing the viewer;

FIG. 2M is a plan view of an outer cover opened and laid flat, innersurface facing the viewer;

FIG. 2N is a plan view of an insert opened and laid flat, outer(garment-facing) surface facing the viewer;

FIG. 3 is a perspective view of a disposable absorbent insert shownapart from an outer cover, as it might appear in a free-standing,relaxed state;

FIG. 4 is a plan view of a disposable absorbent insert shown stretchedout and laid flat, body-facing surfaces facing the viewer;

FIG. 5A is a cross sectional view of an example of an insert such asshown in FIG. 4, taken at line 5A-5A in FIG. 4;

FIG. 5B is a cross sectional view of an example of an insert such asshown in FIG. 4, taken along line 5B-5B in FIG. 4;

FIG. 5C is a cross sectional view of another example of an insert suchas shown in FIG. 4, taken along line 5C-5C in FIG. 4;

FIG. 5D is a cross sectional view of another example of an insert suchas shown in FIG. 4, taken along line 5D-5D in FIG. 4;

FIG. 5E is a cross sectional view of another example of an insert suchas shown in FIG. 4, taken along line 5E-5E in FIG. 4;

FIG. 5F is a cross sectional view of another example of an insert suchas shown in FIG. 4, taken along line 5F-5F in FIG. 4;

FIG. 6 a is a front view of fixtures used on a constant rate ofextension tensile tester for use in the Edge Deflection ForceMeasurement Method herein, with an included test sample;

FIG. 6 b is a side view of a lower fixture used on a constant rate ofextension tensile tester for use in the Edge Deflection ForceMeasurement Method herein;

FIG. 7 illustrates preparation of a test sample of an insert includingan end support stiffener, for testing in the Edge Deflection ForceMeasurement Method herein;

FIG. 8 is a front view of a lower fixture used on a constant rate ofextension tensile tester for use in the Bending Stiffness MeasurementMethod herein;

FIG. 9 is a side view of an upper fixture used on a constant rate ofextension tensile tester for use in the Bending Stiffness MeasurementMethod herein;

FIG. 10 is a front view of an upper fixture used on a constant rate ofextension tensile or use in the Bending Stiffness Measurement Methodherein; and

FIG. 11 is a graph showing Peak Bending Force and slope calculationareas on a bending curve.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

For purposes of this description, the following terms have the meaningsset forth:

“Absorbent insert” and “insert” mean a component of a wearable absorbentarticle that is adapted to contain and/or absorb urine, feces, menses orany combination thereof, and is adapted to be installable and removableas a modular unit, from an outer cover. Herein, an absorbent insert mayalso be referred to as an “absorbent assembly”. The terms “absorbentinsert,” “insert” and “absorbent assembly” may be used interchangeablyherein.

“Chassis” means a component of a wearable absorbent article that isadapted to be worn about the lower torso of a wearer, and is adapted tosupport an absorbent insert and hold the insert next to the wearer'sbody. Herein, a chassis may also be referred to as an “outer cover”. Theterms “outer cover” and “chassis” are interchangeable for purposesherein.

“Disposable”, when referring to an absorbent insert, means that theabsorbent insert is not adapted or intended to be effectively sanitarilylaundered in an ordinary household laundering process and ordinaryhousehold equipment, and thereby is ordinarily unsuitable for sanitaryand effective reuse so as to provide as-new intended functions andperformance, following soiling by exudates and removal from an outercover. By way of non-limiting examples, effective laundering may befrustrated or prevented, causing the insert to be disposable, byinclusion of materials and/or construction: that do not retain theirsubstantial as-new physical shape or structure through ordinaryhousehold laundering and drying so as to be effective as-new in reuse;that absorb aqueous liquids and cannot be sufficiently dried/dehydratedin ordinary household drying equipment and ordinary drying cycles so asto be effective as-new in reuse; that dissolve or substantially degradein ordinary household laundering or drying, causing the insert to besubstantially damaged or rendered useless; and/or that cannot beeffectively cleaned of exudate material through ordinary laundering, soas to be sanitary and otherwise acceptable for re-use.

“Fastener component” means any component of a system that effectsremovable fastening, attachment or holding of a first structure to asecond structure. The system may have a single fastener component, forexample, an adhesive patch on the first structure adapted to adhere toone or more types of surfaces on the second structure, or a hook, orpatch of hooks on the first structure, adapted to catch on one or moretypes of surfaces on the second structure. By way of further example,any structure such as a pocket, strap, hook, buckle, etc. on a firststructure adapted to capture and retain, in whole or in part, the secondstructure, is a “fastener component” as used herein. The system also maycomprise two or more fastener components, for example, respectivecomponents of a hook-and-loop fastening system such as VELCRO),respective surfaces having a cohesive material applied thereto; male andfemale snap fastener components, a button and button hole, slot or loop,other fastenably cooperating elements, etc. Other examples of fastenercomponents include zipper components, “zip lock” engaging components,loops, posts, pockets, bands or straps, microfasteners, macrofasteners,and fastener components such as described in U.S. Pat. Nos. 6,936,039;6,893,388; 6,669,618; 6,432,098; and 6,251,097, and U.S. PublishedApplications, Pub. Nos. 2005/0234419; 2005/0215971; 2005/0215970;2005/0130821; 2004/0023771; 2003/0233082; 2003/0119641; 2003/0088220;and 2002/0169431.

“Lateral” (and forms thereof), with respect to a wearer, means along adirection generally transverse or across the direction extending fromthe front to the rear of the wearer, or vice versa. With respect to acomponent of a wearable absorbent article, “lateral” (and formsthereof), means along a direction generally transverse or across thedirection extending along the component as it would be properly situatedon a wearer, from the front to the rear of the wearer, or vice versa.

“Longitudinal” (and forms thereof), with respect to a wearer, meansalong a direction generally extending from the front to the rear of thewearer, or vice versa. With respect to a component of a wearableabsorbent article, “longitudinal” (and forms thereof), means along adirection generally extending along the component as it would beproperly situated on a wearer, from the front to the rear of the wearer,or vice versa.

“Outer cover” means a component of a wearable absorbent article that isadapted to be worn about the lower torso of a wearer, and is adapted tosupport an absorbent insert and hold the insert next to the wearer'sbody. Herein, an outer cover may also be referred to as a “chassis”. Theterms “outer cover” and “chassis” are interchangeable for purposesherein.

“Reusable”, when referring to an outer cover, means an outer cover thatis adapted to permit removal of at least a first insert, and replacementthereof with at least a second insert, without substantial destructionof any components of the outer cover that are necessary to provide thesubstantial as-new functionality of the outer cover, and without thenecessity of any repair or reconstruction following such insertreplacement.

“Use,” with respect to an outer cover, means one event of the wearing ofthe outer cover until the time an absorbent insert is replaced.

“User” means a caregiver or other person who may apply a wearableabsorbent article to a wearer. Where the wearer is capable of donningthe wearable absorbent article him/herself, the wearer is also a “user”.

“Wearer” means a person who may wear a wearable absorbent article asdescribed herein.

“Wearable absorbent article” means any article designed to be worn aboutthe lower torso and to contain and/or absorb urine, feces, menses or anycombination thereof. “Wearable absorbent article” includes but is notlimited to baby or children's diapers (of the “tape”-fastenable,otherwise fastenable, “pull-up” or any other variety), training pantsand adult incontinence pants, briefs and the like.

Two-Piece Wearable Absorbent Articles

FIG. 1 depicts an example of a wearable absorbent article 10 havingcertain features, as it might appear while being worn by a wearer.Wearable absorbent article 10 may include an outer cover 20, havingfront waist edge 21, rear waist edge 22, and a pair of leg opening edges23.

FIGS. 2A, 2B and 2C depict an outer cover 20 as it may appear opened andlaid flat. In FIG. 2A, the outer, i.e., garment-facing, surfaces ofouter cover 20 face the viewer; in FIGS. 2B and 2C, the inner, i.e.,wearer-facing, surfaces of outer cover 20 face the viewer. Front andrear waist edges 21, 22 are depicted at the top and bottom of thedrawings, respectively. Outer cover 20 may have crotch region 26, frontregion 27, rear region 28 and a pair of fastening ears 29 laterallyextending from rear region 28. Outer cover 20 will have a length LC fromthe forwardmost portion of front waist edge 21 to the rearwardmostportion of rear waist edge 22, and an outer cover lateral axis 45equally dividing this length. Thus, front region 27 is forward of outercover lateral axis 45, and rear region 28 is rearward of outer coverlateral axis 45. Outer cover 20 may have disposed thereon one or moreinsert fastener components such as front and rear insert fastenercomponents 33, 32.

FIG. 3 depicts a disposable absorbent insert 50 that may form an innercomponent of the wearable absorbent article 10, shown in perspectiveview as it might appear in a free-standing, relaxed state, apart fromouter cover 20. Insert 50 may be designed to contain and/or absorb bodyexudates, and may be made of pliable materials as will be describedfurther below. Insert 10 has forward region 54 and rearward region 55,and may include front fastener component 56 and rear fastener component57. Insert 10 may include a body-facing liner or topsheet 51, outerliner or backsheet 52, and a pair of standing cuffs 53. Referring toFIG. 4, insert 50 will have a length L from the forwardmost portion offorward region 54 to the rearwardmost portion of rearward region 55, andan insert lateral axis 70 equally dividing this length. Thus, forwardregion 54 is forward of insert lateral axis 70, and rearward region 55is rearward of insert lateral axis 70.

Referring to FIGS. 2B and 3, insert 50 may have rear fastener component57 disposed thereon. Alternatively, or in addition, outer cover 20 mayhave rear insert fastener component 32 disposed thereon. Similarly,insert 50 may have front fastener component 56 disposed thereon.Alternatively, or in addition, outer cover 20 may have front insertfastener component 32 disposed thereon. If a two-component fasteningsystem is used, fastener component pairs 57, 32 and 56, 33 may becooperating components that effect fastening therebetween when theserespective components are brought together. Thus, in the exampledepicted, in order to install absorbent insert 50 into outer cover 20, auser may lay outer cover 20 flat, inner surface 25 facing up, stretchand orient insert 50 such that rear fastener component 57 faces rearinsert fastener component 32 and front fastener component 56 faces frontinsert fastener component 33, and bring these respective fastenercomponent pairs 57, 32 and 56, 33 together to effect fasteningtherebetween.

If it is desired that outer cover 20 be reusable, for outer cover 20 toremain substantially sanitary and useful (without requiring launderingor disposal) after removal and replacement of an insert, it may bedesired that all parts of outer cover 20 remain substantially unsoiledafter an exudation of waste (especially fecal matter) by the wearer.Thus, it may be desired that when insert 50 is installed within an outercover 20, there is no non-removable portion or component of outer cover20 that lies over or covers a substantial portion of wearer-facingsurfaces of insert 50 (expressed differently, no non-removable portionor component of outer cover 20 is situated between a substantial portionof insert 50 and the wearer when the wearable absorbent article isworn), at least in the areas proximate to wearer body features thatdischarge exudates. Thus, it may be desired that outer cover 20 includeno non-removable cover sheet or the like that covers or containssubstantial portions of wearer-facing surfaces of insert 50 within outercover 20, nor any overlying structures such as pockets, straps or flapsthat substantially wrap or cover the insert proximate to exudatedischarge points, or lie substantially between insert 50 and thewearer's anus and/or genitals, when the wearable absorbent article isworn. If outer cover 20 lacks such overlying structures, this mayincrease the likelihood that the wearer's exudates will contact onlyinsert 50, and not portions of outer cover 20.

Referring to FIGS. 1, 2A and 2B, it can be seen that wearable absorbentarticle 10 may be placed on a wearer by wrapping outer cover 20 betweenthe wearer's legs and under the buttocks such that crotch region 26 isbetween the wearer's legs, bringing front waist edge 21 and rear waistedge 22 into the positions approximately as shown in FIG. 1, and thensecuring fastening ears 29 to front region 27, thereby forming apant-like garment about the wearer as suggested in FIG. 1. When insert50 has been installed into outer cover 20, insert 50 will then bedisposed within outer cover 20, next to the wearer, with the standingcuffs 53 oriented and extending longitudinally adjacent the innerportions of leg edges 23 (i.e., longitudinally between the wearer'slegs).

Examples of Possible Outer Cover Details

Fastening System

Referring to FIGS. 2A and 2B, to enable fastening of fastening ears 29to front region 27, fastening ears 29 may have outer cover fastenercomponents 30 disposed thereon. Alternatively, or in addition, frontregion 27 may have disposed thereon one or more receiving fastenercomponents 31 disposed thereon. Fastener components 30, 31 may beselected so as to be cooperative to effect fastening of ears 29 to frontregion 27.

In one example, outer cover fastener components 30 may include a patchof hooks, and receiving fastener component 31 may include a patch ofloops. An example of a suitable hook-and-loop fastening system is aVELCRO system (a product of Velcro Industries B.V.) A hook-and-loopfastening system provides certain advantages. Because the respectivehook and loop components are supplied in sheet form, they may be cutinto suitably shaped patches that can be affixed to a cloth or nonwovensubstrate by various mechanisms, including adhesive bonding, mechanicalbonding, ultrasonic bonding, sewing, stitching, serging, edging, and thelike. If patches of hooks or loops are affixed to fastening ears 29 toform outer cover fastener components 30, as suggested by FIG. 2B, alaterally extended patch of cooperating hook or loop material can beaffixed to outer cover front region 27 to form a receiving fastenercomponent 31, as suggested by FIG. 2A. By providing for fastening ofears 29 to front region 27 at laterally varying locations thereon, thisarrangement provides for easy and simple adjustability of waist openingsize of the wearable absorbent article.

In another example, as noted above, the outer cover fastening system mayinclude other types of fastener components. To provide for waist openingsize adjustability, fastener components disposed on fastening ears 29that cooperate with extended surfaces or multiple cooperating fastenercomponents disposed on front region 27 may be used. Receiving fastenercomponents may be multiply disposed on front region 27 in laterallyarranged, varying locations, allowing for fastenability of respectiveears 29 to front region 27 at laterally varying locations.

Referring to FIG. 2B, outer cover 20 also may have one or morerespective fastener protectors 39 disposed thereon. This feature mayprevent fastener components having features likely to randomly andunintentionally engage and catch on portions of the outer cover, orother articles, during storage, carrying, laundering and similar/relatedactivities, from doing so, thereby avoiding potential bunching,entangling and/or damage to either outer cover 20 or other articlesduring such activities. For example, if fastener components 30 arepatches of hooks, appropriately placed fastener protectors 39 mayinclude patches of corresponding loops. This will enable the user tofold ears 29 over to engage them with fastener protectors 39, therebyholding them in the folded-over position such that hooks thereon will beconcealed and prevented from snagging other articles when outer cover 20is not being worn.

Materials

Outer cover 20 and/or layers or portions thereof may be made of anyknitted, woven or nonwoven textile or textile-like material that isappropriately compatible with skin of the intended wearer(s). Outercover 20 may be constructed of durable and/or semi-durable materials.Generally, only for purposes of reference in this description, “durable”refers to a woven or knitted textile material of any kind that may beused as a component of a washable clothing article. As used herein,“durable” includes materials which are “launderable” as defined anddescribed in co-pending U.S. application Ser. Nos. 12/687,412;12/687,528; and 12/687,425, entitled, respectively, “REUSABLE OUTERCOVER FOR AN ABSORBENT ARTICLE,” “REUSABLE OUTER COVER FOR AN ABSORBENTARTICLE HAVING ZONES OF VARYING PROPERTIES,” and “LEG AND WAISTBANDSTRUCTURES FOR AN ABSORBENT ARTICLE,” by Donald C. Roe, filed on thesame day hereof. Generally, only for purposes of this description,“semi-durable” refers to a nonwoven material or laminate thereof thatwhen used as an outer cover material can withstand more than one usewith an insert without losing its structural integrity to an extent thatrenders it unserviceable. As used herein, “semi-durable” includesmaterials which are “laundering resistant” as defined and described inthe co-pending U.S. applications identified immediately above. Thus,outer cover 20 may be constructed of materials and construction thatmake it reusable and/or washable.

Durable materials of which outer cover 20 may be constructed may includeany natural or synthetic textile materials known in the diaper, pant,underwear, performance clothing, sport clothing, or general clothing ortextile arts. Durable materials may include woven or knitted textilesmade of natural fibers such as cotton, linen, wool, bamboo, hemp, silk,rayon, and the like, as well as blends of any of these fibers with anyother(s), or with synthetic fibers. Examples of synthetic fiberssuitable for use as components of durable materials include polyester,nylon, spandex and/or other elastomer fibers. Durable outer covermaterials also may include breathable water repellent materials such asGORE-TEX (a product of W. L. Gore & Associates, Inc., Elkton, Md.),fabrics comprising microencapsulated phase-change polymer materials suchas OUTLAST COMFORTEMP fabrics (products of Outlast Technologies,Boulder, Colo.—see U.S. Pat. No. 6,514,362 and U.S. Pat. No. 6,207,738,for example), COOLMAX (a product of Invista, Wichita, Kans.), and thelike.

Suitable durable materials may be formed in any weave or knit fabricform, including birdseye fabric, terry, fleece, flannel, knits, stretchknits, sherpa, suedecloth, microfleece, satin, velour, Burley knits,etc. Suitable examples include POLARTECH POWER DRY, POWER STRETCH andWIND PRO (products of Polartec, LLC, Lawrence, Mass.). Knitted textiles,which may be more inherently stretchable and elastic than woven ornonwoven materials, may impart better fit, comfort and/or appearance tothe outer cover. Incorporation of fibers of spandex or other elastomeralso may also enhance stretchability and elasticity, and thereby impartbetter fit, comfort and/or appearance to the outer cover, than textilesnot including such elastomeric fibers.

Specific suitable examples for durable outer cover materials includejersey knits of blends of: rayon (93%) and spandex (7%) fibers; modal(94%) and spandex (6%) fibers; cotton and spandex fibers; and bamboo andspandex fibers. Materials that have stretch capability of equal to orgreater than about 2× may be desired. Suitable examples of materials mayhave basis weights of about 0.09-0.15 gram/in.² per layer, or otherbasis weights.

Durable outer cover materials may be selected to impart desired comfort,appearance and performance to outer cover 20. In some circumstances itmay be desired to select durable outer cover materials which aresufficiently inexpensive to allow for disposal, if soiled extensively ordamaged, with minimized issues of cost or conscience.

Semi-durable outer cover materials may include any natural or syntheticnonwoven web and/or film materials known in the diaper or pant arts.Semi-durable materials of which outer cover 20 may be constructed mayinclude non-woven web materials of polypropylene and/or polyethylenefibers, polyester fibers, and any other synthetic fibers used to formnonwoven web materials used as components of disposable diapers, andblends thereof. Natural fibers such as cotton, linen, wool, bamboo,hemp, silk, rayon, and the like may be blended with synthetic fibers toform such a nonwoven web suitable as a component layer of outer cover20.

Non-limiting examples of fibers, nonwovens and laminates of nonwovensand films that might be considered for use as semi-durable outer covermaterials may be found in U.S. Pat. Nos. 7,223,818; 7,211,531;7,060,149; 6,964,720; 6,905,987; 6,890,872; 6,884,494; 6,878,647; and5,518,801; and U.S. Published Applications Nos. 2008/0319407;2008/0045917; 2007/0293111; 2007/0287983; 2007/0287348; 2007/0249254;2007/0203301; and 2005/0164587.

Semi-durable outer cover materials also may be selected to impartdesired comfort, appearance and performance to outer cover 20. In somecircumstances it also may be desired to select semi-durable outer covermaterials which are sufficiently inexpensive to allow for disposal, ifsoiled extensively or damaged, with minimized issues of cost orconscience.

The outer cover also, or additionally, may include a laminated orsubstantially separate film layer, which may be elastic, to provideenhanced liquid penetration resistance and/or elastic properties.Elastic properties also can be added or enhanced via the addition ofother materials to the outer, cover in layer, band or strip fashion,including elastic strands, bands, scrims, and the like. A film layer maybe laminated with a durable material or semi-durable material. A filmlayer may include an elastomer based on KRATON (a product of KratonPolymers U.S., LLC, Houston, Tex.), or by way of further example,VISTAMAXX available from ExxonMobil Chemical Company, Houston, Tex.;FLEXAIRE, EXTRAFLEX or FABRIFLEX (products of Tredegar Film ProductsCorporation, Richmond, Va.), and various latex-free elastomeric sheetsavailable from Fulflex Elastomerics Worldwide (Greenville, Tenn.).

Inclusion of an elastomeric material, either as a fibrous component of acloth or nonwoven layer, or as a film layer, provides for improvedstretchability and elasticity where it may be deemed useful toaccommodate the wearer's anatomy and movements, such as over thewearer's buttocks and/or around the waist areas, and improved fit andcomfort. Additionally, where a film layer may be included, it may impartadditional liquid containment capability to the outer cover. A filmlayer may include a film that is substantially liquid impermeable, butvapor permeable, so as to provide breathability and reduce humiditywithin the outer cover while it is being worn, reducing chances forover-hydration of the skin where liquid containment capability isdesired. A breathable film also may be provided by mechanicallyperforating or aperturing a film by various processes. Examples of suchprocesses are described in co-pending U.S. application Ser. Nos.12/366,825 and 12/534,353.

Referring to FIG. 2A, in one example outer surface 24 may be formed by afirst layer of a durable or semi-durable material. The material selectedmay include fibers having hydrophobic properties, providing enhancedliquid containment attributes to such first layer. In another example,however, it may be desirable in some circumstances for the selectedmaterial to include hydrophilic fibers, or fibers treated to behydrophilic, so as will cause the material to more readily absorb and/ortransmit liquid therethrough. This may serve to provide supplementalabsorbency within the outer cover for the event in which liquid exudatesescape the insert, or to provide one way of communicating to the userthat liquid exudates have escaped the insert. Additionally, in somecircumstances it may be desirable that the material selected have softtactile properties so as to have a pleasant feel that the user and/orwearer find attractive. The material also may be selected so as to havea desired appearance, including but not limited to coloration, sheen,texture, etc.

Outer cover 20 may be formed of a single layer of a durable orsemi-durable material, or may have two or more layers in the frontregion 27 and/or rear region 28. Accordingly, referring to FIG. 2B, inanother example inner surfaces 25 may be formed by a second layer of adurable or semi-durable material. The material selected may includefibers having hydrophobic properties, providing enhanced liquidcontainment attributes to the second layer. In another example, however,it may be desirable in some circumstances for the selected material toinclude hydrophilic fibers, or fibers treated to be hydrophilic. Thismay be desired in some circumstances to cause the material forming innersurfaces 25 to more readily absorb liquid, or transmit liquidtherethrough. This may serve to provide supplemental absorbency withinthe outer cover for an event in which liquid exudates escape the insert,reducing the likelihood that the outer cover will leak. Alternatively,it may provide one way of communicating to the user that liquid exudateshave escaped the insert, by causing wetness to be transmitted through tothe outer cover outer layer such that wetness is visible on outersurfaces. Alternatively, it may serve to provide a layer that tends todraw moisture away from the skin, for a drier, more comfortable feel.

Additionally, in some circumstances it may be desirable that thematerial(s) selected for inner surfaces 25 have soft tactile propertiesso as to have a pleasant feel against the skin, particularly in areaswhere no portion of an insert is expected to be present between theouter cover and the wearer's skin.

In another example, the second layer of material may be formed of atextile material having enhanced elasticity, such as by inclusion offibers of an elastomeric material (such as spandex). In another example,an intermediate film layer may be included, laminated or not laminatedwith another layer.

Forming the outer cover 20 of more than one layer, for example, two, ormore, layers, as described above, may provide various benefits. A secondlayer (and any additional layers) may provide supplemental tensilestrength in both the lateral and longitudinal directions across theouter cover 20. Additionally, a first layer may be selected for a firstset of properties, and a second layer may be selected for a second setof properties. For example, material forming a first layer may beselected for having comparatively greater elasticity and a particulartexture, color and/or other appearance-related properties, and materialforming a second layer may be selected for having comparatively greaterhydrophobicity, hydrophilicity and/or softness to the skin for purposesof an inner layer, the two layers in combination imparting a combinationof desirable attributes to the outer cover. For example, the inner layermay be formed of material(s) and/or treated to be more hydrophilic so asto provide for absorbency and reduced chances of fluid runoff (leakage),while the outer layer may be formed of material(s) that are morehydrophobic, so as to, e.g., resist environmental soiling, or resistliquid transmission from the inner layer to the outer layer.Additionally, a plurality of layers may better serve to conceal bumps,corners, seams or other features of an insert, as compared with a singlelayer, for a smoother, more attractive appearance.

In addition to forming differing layers of differing materials, it maybe desirable to form a single layer of differing materials, for example,differing materials in the respective front, crotch and/or rear regionsof the outer cover. Such differing materials may be joined at a seamsuch as inner seam 40 and/or outer seam 41. For example, the materialpredominately forming the inner surface of rear region 28 may beselected primarily for its elasticity features, which may better serveto provide snug fit about wearer body contours and accommodate wearermovement (i.e., about the buttocks and hips). By comparison, thematerial predominately forming the inner surface of front region 27and/or crotch region 26 might be selected primarily for itshydrophobicity or hydrophilicity, which may better serve to containliquid exudates.

Layers or other elements of the outer cover may be joined to each othervia any suitable mechanism, including, for example, adhesives,mechanical bonding, ultrasonic bonding, sewing, stitching, serging,edging, and the like.

Additionally or alternatively to the constructions and materialsdescribed above, the outer cover may be constructed and may includematerials and features as described in co-pending U.S. application Ser.Nos. 12/687,412; 12/687,528; and 12/687,425, entitled, respectively,“REUSABLE OUTER COVER FOR AN ABSORBENT ARTICLE,” “REUSABLE OUTER COVERFOR AN ABSORBENT ARTICLE HAVING ZONES OF VARYING PROPERTIES,” and “LEGAND WAISTBAND STRUCTURES FOR AN ABSORBENT ARTICLE,” by Donald C. Roe,filed on the same day hereof.

Elasticized Waistbands, Leg Bands

Referring again to FIGS. 1, 2A and 2B, front waist band portion 34, rearwaist band portion 35, and leg band portions 36 are depicted. One ormore of these band portions 34, 35, 36 may be formed of one or morestrands or strips including an elastomeric material such as spandex or ablend of spandex and other fibers, enveloped by a nonwoven or textilematerial, which may include the edges of the material forming the innerand/or outer layers of outer cover 20, to form and elasticize therespective band portions. The elastic material may be affixed to orwithin an outer cover layer in a strained condition, or at zero appliedstrain. Textile material(s) enveloping the elastic strand(s) or strip(s)may be sewn around elastic strand(s) or strip(s) to hold them in placewithin the respective band portions. If the elastic material is strainedprior to, and while, being enveloped and affixed to form these bandportions during the manufacturing process, upon relaxation theenveloping material and adjacent outer cover material may be caused togather and form ruffles 37 therealong, which constitute gathered outercover material. This can serve to promote snug fit, wearer comfort andappearance. The band portion may be disposed along the edge of the outercover, and in some circumstances it may be desired to have the bandportion situated along substantially the entire length of the leg and/orwaist openings so as to form bands that substantially or completelyencircle the wearer's legs and/or waist while outer cover 20 is worn.The gathered material within ruffles 37 can serve to accommodatestretching of waist band portions 34, 35 and leg band portions 36. Thisarrangement including elasticized leg band portions 36 as described, notonly may provide for better fit about the wearer's legs, but also mayenable the outer cover 20, when formed of appropriately sized and shapedmaterial, to form a pouch-like structure 75 in the crotch region (seeFIG. 1) when worn, which may serve to provide space within the outercover to accommodate the insert 50 (FIG. 3) and help hold it in placewithin outer cover 20, in a substantially laterally centered positionwithin the crotch region. This may be deemed advantageous in examples inwhich an insert 50 is attached within outer cover 20 by fastenercomponents only located proximate to the respective ends of insert 50,and not at any longitudinally intermediate locations, as describedfurther below. Alternatively, or additionally, the elastic strands orstrips in waist band portions 34, 35 and leg band portions 36 may beaffixed within the outer cover only at or near their respective ends,e.g., within a pouch, tube or envelope structure formed of outer covermaterial—referred to herein as a “drawstring elastic”. This will allowthe elastic material and associated outer cover material to stretch andmove freely and independently of each other, which may promote fit andcomfort. A snug fit about the wearer's legs provided by such elasticizedleg band portions 36 may serve to enhance containment capability of thewearable absorbent article.

One or more of waist band portions 34, 35 and leg band portions 36 maybe elasticized in the manner described above, or by other mechanisms.For example, elasticized band/strip material such as that used to formelastic waistbands and leg bands or other banding features ofconventional cloth underwear, briefs or other articles of clothing maybe separately produced, and affixed to the materials forming outer cover20 in any suitable manner, during the manufacture thereof.

In another example, one or more of waist band portions 34, 35 and legband portions 36 may be formed of elastic material simply affixed aboutthe leg opening and/or waist opening edges by use of adhesive and/orcompression bonding. In another example, an elastic strip material mayformed by affixing a plurality of strained elastomeric strands or stripsto one or more strips of unstrained nonwoven web material or film. Whenthe resulting elastic strip material is allowed to relax, the unstrainedmaterial forms transverse rugosities that comprise gathered unstrainedmaterial, which will accommodate stretching of the elastic stripmaterial. By affixing the elastic strip material at one or more of waistband portions 34, 35 and/or leg band portions 36, the elastic stripmaterial may be used to form one or more of elasticized waist bandportions 34, 35 and/or leg band portions 36.

Anchoring Bands

Outer cover 20 also may include an anchoring supplement such asanchoring band 38 disposed on or in the outer cover rear region 28 asindicated in FIGS. 2A, 2B. As suggested in FIGS. 2A and 2B, anchoringband 38 may be affixed along a layer, or disposed between layers,forming inner surfaces 25 and outer surfaces 24 of outer cover 20.Anchoring band 38 may include an elastomeric or elasticized strip orband of material, affixed to outer cover 20 at locations proximate toits rearward corners or proximate to fastening ears 29. Thus, anchoringband 38 may be partially or substantially force-decoupled from the otherlayer(s) of the outer cover along its lateral length from the layer(s)forming the inner and outer surfaces of outer cover 20, via attachmentto the outer cover only by the ends of anchoring band 38, or only at alimited number of selected intermediate lateral locations alonganchoring band 38. For example, anchoring band 38 might be attached toouter cover 20 only at the ends of anchoring band 38. In anotherexample, anchoring band 38 might be attached to outer cover 20 only atthe ends and at the lateral center of anchoring band 38. Thissubstantially force-decoupled arrangement allows anchoring band 38 andsurrounding portions of outer cover 20 to stretch and move substantiallyindependently of one another, which may promote better fit and comfort.In another example, however, anchoring band 38 may be an elastic band,strip or strap laminated with or otherwise affixed to a layer ofstretchable material forming either of or both the inner and outersurfaces of the outer cover, along substantially the entire length ofanchoring band 38.

When strained laterally by application to the wearer, anchoring band 38may serve to provide, or supplement, lateral tensile forces in thearticle about the wearer's waist, thereby tending to draw the waistopening snug, enhancing fit and enhancing securement of the wearableabsorbent article about the wearer's waist. The elastic modulus of theanchoring band may be higher than the elastic modulus of thesurrounding, adjacent, or coextensive outer cover materials.

An anchoring band, or system of one or more anchoring band members, mayhave any additional features described in, for example, co-pending U.S.patent application Ser. Nos. 11/810,741; 11/810,708; 12/101,476;12/028,317; 11/810,745; 11/810,742; 11/810,734; 11/810,779; 11/810,715;11/810,733; 11/810,736; 11/810,777; and 11/599,862; 11/810,901 and11/599,851; 11/899,812; 12/204,844; 12/204,849; 12/204,854; 12/204,858;and 12/204,864; 11/899,810; 11/899,656; and 11/899,811; 11/899,812;12/204,844; 12/204,849; 12/204,854; 12/204,858; and 12/204,864; andco-pending U.S. application Ser. Nos. 12/687,437; 12/687,554; and12/687,444, entitled, respectively, “REUSABLE WEARABLE ABSORBENTARTICLES WITH ANCHORING SYSTEMS,” “REUSABLE WEARABLE ABSORBENT ARTICLESWITH ANCHORING SUBSYSTEMS,” and “REUSABLE OUTER COVERS FOR WEARABLEABSORBENT ARTICLES,” by Donald C. Roe, filed on the same day hereof.

In another example, instead of, or in addition to, being orientedsubstantially laterally as suggested by the depicted location ofanchoring band 38 in FIGS. 2A and 2B, one or more members forminganchoring bands may be oriented diagonally between the longitudinal andlateral directions. For example, as suggested in FIG. 2A, a pair ofdiagonal anchoring bands 38 a may have respective waist ends thereofaffixed at a location area proximate to corners of the outer coverand/or fastening ears 29, and respectively extend toward both thelateral and longitudinal center of outer cover 20, as suggested in FIG.2A. The respective center ends of bands 38 a may be affixed to the outercover at locations proximate the lateral center of the outer cover assuggested in FIG. 2A, and bands 38 a may be either force-decoupled orforce-coupled to the outer cover along the lengths of bands 38 a, asdescribed above. In an example where an insert is connected to ananchoring band for additional longitudinal support as described furtherbelow, diagonal anchoring bands such as diagonal anchoring bands 38 amay serve to provide supplementary longitudinal tension along outercover 20, providing supplemental longitudinal support therewithin.

Outer Cover Asymmetry

In order to enhance and/or maximize fit, wearer comfort and appearanceof the outer cover 20, it may be desirable to fashion outer cover 20 soas to accommodate anatomical contours and body movements of the intendedwearer. For example, as suggested by FIGS. 2A and 2B, outer cover 20 mayhave differing shape and/or greater material surface area in the rearregion 28 than in the front region 27. Human anatomy in the lowertorso/hip/thigh region is asymmetric about the lateral plane of thebody, i.e., the geometry of the front of the human body is differentthan that of the back. To provide for better fit and comfort, the outercover geometry and functionality, including stretch properties, may beadapted accordingly. Differing shape and/or greater material surfacearea in the rear region may serve to better cover the buttocks throughmovements of the wearer (including sitting and/or bending forward at thehips), while lesser material surface area in the front region may serveto avoid material bunching and/or an ill-fitting appearance,particularly when the wearer is in positions including sitting and/orbending forward at the hips. As a result, the outer cover may beasymmetric in shape or surface area across outer cover lateral axis 45.

For purposes of this description, when used with respect to an outercover, “asymmetric” and “asymmetry” mean that features, geometry (e.g.,shape), materials and/or construction on one side of outer cover lateralaxis 45 differ substantially in some respect from those on the otherside of outer cover lateral axis 45. Such asymmetric constructionresults from having various features of outer cover 20 designed toaccommodate the body features and functions of the intended wearer asthey differ front-to-rear, to enhance containment/absorbencyperformance, comfort, fit and/or appearance of the wearable absorbentarticle, and/or to economize on use of materials. “Asymmetric” and“asymmetry” do not refer to differences across the outer cover lateralaxis that are attributable to features that may be included on an outercover only for purposes of: purely cosmetic coloration or surfacedecoration; fastening an insert (such as fastener components describedherein); bundling, folding, storing or carrying the outer cover; indiciafor orienting an insert within an outer cover or vice versa (such asorientation indicia described herein), or for other purposessubstantially unrelated to the body features and functions of theintended wearer as they differ front-to-rear, to affect performance,comfort, fit and/or physical appearance of the wearable absorbentarticle, and/or to economize on use of materials.

Other asymmetries across outer cover lateral axis 45 may be present aswell. For example, as suggested by FIGS. 2A and 2B, relatively localizedouter cover fastener components 30 may be respectively disposed onfastening ears 29, while a relatively laterally extended receivingfastener component 31 may be disposed on outer cover front region 27,for purposes of waist opening adjustability as explained above.Fastening ears 29 may form lateral extensions from rear region 28 thatare not present in kind on front region 27. These are examples ofdifferences that create functional and structural asymmetries of theouter cover across outer cover lateral axis 45. Because an absorbentarticle of the type described herein is usually changed while the weareris substantially facing the user, such arrangement enhances userconvenience by locating these fastening and waist opening adjustabilityfeatures at the wearer's front abdominal region, facing the user.

In another example of asymmetry, materials of differing composition,construction and/or properties may predominately form forward region 27as compared with rearward region 28. For example, the material(s)forming rear region 28 may be selected for enhanced stretch/elasticproperties, as compared with material(s) forming front region 27. Inthis example, material(s) with enhanced stretch/elastic properties mayserve to better accommodate, stretch and contract over contours of thebuttocks, and accommodate body movements such as sitting and bendingforward at the hips, thereby providing better coverage and fit.

In still another example of asymmetry, outer cover 20 may havestructures such as elastic bands, anchoring bands and/or other memberswhich differ between front region 27 and rear region 28.

In still other examples of asymmetry, the materials thinning outer cover20 may have, or be imparted with, differing levels of hydrophilicityand/or hydrophobicity, differing levels of breathability, differingcoefficients of friction, and/or other differing functional attributesin the front versus the rear regions.

It will be appreciated, therefore, that outer cover asymmetry acrossouter cover lateral axis 45 is a result of design and construction ofthe outer cover so as to have only one front region and only one rearregion, i.e., the front and rear regions are not interchangeable, if thefit, comfort, performance and appearance of outer cover 20 are to beoptimal.

Examples of Possible Absorbent Insert Details

Examples of features of an absorbent insert 50 will be described withreference to FIGS. 3, 4 and 5A-F.

As noted above, FIG. 3 depicts a disposable absorbent insert 50 that mayform an inner component of a wearable absorbent article as describedherein, shown in perspective view as it might appear in a free-standing,relaxed state, apart from an outer cover. FIG. 4 depicts an example ofan insert 50 shown stretched out and laid flat (against elastic-inducedcontraction to a position similar to that shown in FIG. 3), body-facingsurfaces facing the viewer. FIGS. 5A-5F depict cross sections of aninsert 50 as indicated in FIG. 4, in various possible examples.

Insert 50 may have a topsheet 51 and backsheet 52 forming anenvelope-like enclosure for absorbent core materials such as thosedescribed further below. Topsheet 51 and backsheet 52 may be affixedtogether along longitudinal seams 64, and along lateral seams 69. Insert50 also may have longitudinal standing cuffs 53 affixed therealong.

Topsheet

Topsheet 51 may be formed of a liquid-permeable nonwoven web material.It may be desired that material forming topsheet 51 is compliant,soft-feeling, and non-irritating to the wearer's skin. It may be desiredthat at least a portion of topsheet 51 may be liquid pervious,permitting liquids to readily penetrate through its thickness. Asuitable topsheet may be manufactured from a wide range of materials,such as porous foams, reticulated foams, apertured plastic films, orwoven or nonwoven materials of natural fibers (e.g., wood or cottonfibers), synthetic fibers (e.g., polyester or polypropylene fibers), ora combination of natural and synthetic fibers. If topsheet 51 includesfibers, the fibers may be spunbond, carded, wet-laid, meltblown,hydroentangled, or otherwise processed as is known in the art.

One suitable material comprising a nonwoven web of staple-lengthpolypropylene fibers is manufactured by Veratec, Inc., a Division ofInternational Paper Company, of Walpole, Mass. under the designationP-8. Additional suitable materials comprising formed films are describedin U.S. Pat. Nos. 3,929,135; 4,324,246; 4,342,314; 4,463,045; and5,006,394. Other suitable topsheets 30 may be made in accordance withU.S. Pat. Nos. 4,609,518 and 4,629,643. Suitable examples of formedand/or apertured films may include products produced by The Procter &Gamble Company of Cincinnati, Ohio as DRI-WEAVE, and by TredegarCorporation, based in Richmond, Va., as FRESHFEEL. Suitable topsheetmaterials also may include laminates of films and nonwoven webs producedby Tredegar as COMFORTFEEL, COMFORTQUILT, SOFTQUILT and COMFORTAIRE.

In some circumstances it may be desired that at least a portion oftopsheet 51 is made of a hydrophobic material or is treated to behydrophobic in order to isolate the wearers skin from liquids containedin absorbent core 71. If topsheet 51 is generally made of a hydrophobicmaterial, it may be desired that at least a portion of the upper surfaceof topsheet 51 is treated to be hydrophilic so that liquids willtransfer through the topsheet more rapidly. Topsheet 51 can be renderedhydrophilic by treating it with a surfactant or by incorporatingsurfactant into the topsheet. Suitable methods for treating topsheet 51with a surfactant include spraying the topsheet material with thesurfactant and/or immersing the material into the surfactant. A moredetailed discussion of such a treatment and hydrophilicity is containedin U.S. Pat. Nos. 4,988,344 and 4,988,345. A more detailed discussion ofsome suitable methods for incorporating a surfactant in the topsheet canbe found in U.S. Statutory Invention Registration No. H1670. In anotherexample, however, topsheet 51 may include an apertured web or film whichis hydrophobic. This may be accomplished by foregoing the hydrophilizingtreatment step from the production process and/or applying a hydrophobictreatment to the topsheet material, such as a polytetraflouroethylenecompound like SCOTCHGUARD or a hydrophobic lotion composition, asdescribed below. In such examples, it may be desired that the aperturesbe large enough to allow the penetration of aqueous fluids like urinewithout significant resistance otherwise attributable to hydrophobicity.It may also be desired that the apertures have sufficient effective openarea and/or aperture size to allow the penetration of low-viscosityfecal material. Examples of topsheets meeting these requirements aredescribed in U.S. Pat. Nos. 5,342,338; 6,414,215; and 6,010,491.

Any portion of topsheet 51 may be coated with a lotion or skin carecomposition as is known in the art. Examples of suitable lotions includethose described in U.S. Pat. Nos. 5,607,760; 5,609,587; 5,635,191;5,643,588; 5,968,025 and 6,716,441. The lotion may function alone or incombination with another agent as the hydrophobizing treatment describedabove.

Topsheet 51 may also include or be treated with antibacterial agents,some examples of which are disclosed in U.S. application Ser. No.08/212,441, published as U.S. Statutory Invention Registration H1732.

Topsheet 51, backsheet 52 or any portion of the topsheet or backsheetmay be embossed and/or matte finished to provide a more cloth-likeappearance.

Topsheet 51 may be fully or partially elasticized or may beforeshortened so as to provide a void space between topsheet 51 and core71. Exemplary structures including elasticized or foreshortenedtopsheets are described in more detail in U.S. Pat. Nos. 4,892,536;4,990,147; 5,037,416; and 5,269,775.

Backsheet

Backsheet 52 is generally that outer liner portion of insert 50 formingthe garment-facing surface thereof, and prevents the exudates absorbedand contained within insert 50 from wicking through and soiling theouter cover. In some circumstances it may be desired that backsheet 52is substantially impervious to liquids.

Backsheet 52 may be formed of a film, a nonwoven, or a laminate of afilm and a nonwoven. Backsheet 52 may be formed of a substantiallyliquid-impermeable laminate or composite of film and non-woven web.Backsheet 52 may be formed of a substantially liquid impermeablenonwoven web, or laminate of nonwoven web and substantially liquidimpermeable film, so as to contain and isolate liquid exudates from theouter cover, outer clothing and/or environment of the wearer. At thesame time, backsheet 52 may be vapor permeable to provide forbreathability of the insert and the wearable absorbent article, reducinghumidity in the areas between the insert and the wearer's body, andhelping reduce the likelihood of skin irritation and/or rashes that mayresult from over-hydration of the skin.

The material forming backsheet 52 may include a thin plastic film suchas a thermoplastic film having a thickness of about 0.012 mm (0.5 mil)to about 0.051 mm (2.0 mils). Suitable backsheet materials also may bebreathable materials which permit vapors to escape while stillpreventing liquid from passing therethrough. Suitable examples mayinclude those manufactured by Tredegar Corporation, based in Richmond,Va., and sold under the trade names CPC2, X15306, X10962 and X10964film. Other examples may include microporous films such as manufacturedby Mitsui Toatsu Co., of Japan under the designation ESPOIR NO and byExxon Chemical Co., of Bay City, Tex., under the designation EXXAIRE,and monolithic films such as manufactured by Clopay Corporation,Cincinnati, Ohio under the name HYTREL blend P18-3097. Some additionalexamples may include breathable composite materials as described in PCTApplication No. WO 95/16746; and U.S. Pat. Nos. 5,938,648; 5,865,823;and 5,571,096. In other examples, backsheet 52 may comprise elastomericfilms, foams, strands, or combinations of these or other suitablematerials with nonwovens or synthetic films.

In certain embodiments, the backsheet may have a water vaportransmission rate (WVTR) of greater than about 2000 g/24 h/m², greaterthan about 3000 g/24 h/m², greater than about 5000 g/24 h/m², greaterthan about 6000 g/24 h/m², greater than about 7000 g/24 h/m², greaterthan about 8000 g/24 h/m², greater than about 9000 g/24 h/m², greaterthan about 10000 g/24 h/m², greater than about 11000 g/24 h/m², greaterthan about 12000 g/24 h/m², greater than about 15000 g/24 h/m², measuredaccording to WSP 70.5 (08) at 37.8° C. and 60% Relative Humidity. Ahigher WVTR may be desired in this particular application, since theinsert backsheet 52 will not form the outer surface of the wearablearticle, as a conventional disposable diaper backsheet would, butrather, will be covered by the one or more layers of the outer covermaterial(s)—which themselves may act in some circumstances to reduceWVTR of the composite structure.

Backsheet 52 may be joined to topsheet 51, absorbent core 71 or anyother element of insert 50 by any suitable attachment mechanism known inthe art. For example, the attachment mechanism may include a continuousline or layer of adhesive, a patterned layer of adhesive, or an array ofseparate lines, spirals, or spots of adhesive. One example of anattachment mechanism comprises an open pattern network of filaments ofadhesive as disclosed in U.S. Pat. No. 4,573,986. Other suitableattachment mechanisms include several lines of adhesive filaments whichare swirled into a spiral pattern, as is illustrated by the apparatusand methods shown in U.S. Pat. Nos. 3,911,173; 4,785,996; and 4,842,666.Adhesives which have been found to be satisfactory are manufactured byH. B. Fuller Company of St. Paul, Minn. and marketed as HL-1620 andHL-1358-XZP. Alternatively, the attachment mechanism may comprise heatbonds, pressure bonds, ultrasonic bonds, dynamic mechanical bonds, orany other suitable attachment mechanisms or combinations of theseattachment mechanisms known in the art.

It will be appreciated that the outer cover described above can beconstructed of materials and construction so as to bear and sustain amajority of the structural loading generally imposed upon a disposablediaper, by stretching and accommodation of the wearer's anatomicalfeatures and body movements, and by absorption, swelling and addedweight resulting from the wearer's exudations of waste. Thus, lesserrequirements for structural strength of an insert might be present withuse of such an outer cover, as compared with strength required of insidecomponents of a disposable diaper. Therefore, an article such asdescribed herein may include a disposable absorbent insert manufacturedfrom materials that are different from those ordinarily used in themanufacture of disposable diapers, such as petroleum-derived materials,e.g., polyethylene and polypropylene. For example, a disposableabsorbent insert having one or more of a topsheet, backsheet, standingcuffs and/or other components formed of products of wood, cotton, flax(linen), hemp, bamboo, or other cellulose fibers (e.g., paper), inaddition to the materials identified above, is contemplated. Ifresistance to aqueous liquid penetration or substantial liquidimpermeability is desired, e.g., for a backsheet and/or standing cuffs,a material formed of ordinarily hydrophilic fibers such as paper may becoated or impregnated with a hydrophobic material, such as askin-compatible oil or wax, to impart the desired resistance to aqueousliquid penetration. Each of the materials forming the insert may beselected so as to be dispersible in water or an aqueous solution,flushable, biodegradable and/or compostable (preferably to anagriculturally usable humus or soil amendment).

Absorbent Core

Referring to FIGS. 5A-F, insert 50 may have an absorbent core 71 withinthe envelope-like structure formed by topsheet 51 and backsheet 52.Absorbent core 71 may comprise any absorbent material which is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine and othercertain body exudates. Absorbent core 71 may comprise a wide variety ofliquid-absorbent materials commonly used in disposable diapers and otherabsorbent articles such as comminuted wood pulp, which is generallyreferred to as airfelt. Examples of other suitable absorbent materialsinclude creped cellulose wadding; meltblown polymers, including coform;chemically stiffened, modified or cross-linked cellulosic fibers;tissue, including tissue wraps and tissue laminates; absorbent foams;absorbent sponges; superabsorbent polymers; absorbent gelling materials;or any other known absorbent material or combinations of materials.

Absorbent core 71 may include liquid acquisition/distribution material65, and storage material 66. Generally, acquisition/distributionmaterial 65 may have comparatively rapid absorption and wickingproperties, but also may have limited absorption capacity. Conversely,generally, storage material 66 may have comparatively slower absorptionand wicking properties, but also may have greater absorption capacity.Thus, acquisition/distribution material 65 may serve to rapidly absorband distribute gushes of liquid such as urine, while storage material66, having greater absorption capacity, may serve to absorb such liquidfrom the acquisition/distribution material and store it for the timeneeded until the insert may be replaced.

Absorbent core 71 may be manufactured in a wide variety of sizes andshapes (e.g., rectangular, hourglass, “T”-shaped, etc.). Theconfiguration and construction of absorbent core 71 may also be varied(e.g., the absorbent core(s) or other absorbent structure(s) may havevarying caliper zones, hydrophilic gradient(s), a superabsorbentgradient(s), or lower average density and lower average basis weightacquisition zones; or may comprise one or more layers or structures).Examples of absorbent structures for use as absorbent core 71 mayinclude those described in U.S. Pat. Nos. 4,610,678; 4,673,402;4,834,735; 4,888,231; 5,137,537; 5,147,345; 5,342,338; 5,260,345;5,387,207; and 5,625,222.

To reduce the overall size and/or thickness of the absorbent core, andthereby improve wearer comfort and reduce the volume of disposable wastecreated by a soiled insert, it may be desired to construct an absorbentcore using the lowest volumes of core materials possible withinperformance constraints. Toward this end, examples of suitable materialsand constructions for a suitable absorbent core are described in, butare not limited to, copending U.S. application Ser. Nos. 12/141,122;12/141,124; 12/141,126; 12/141,128; 12/141,130; 12/141,132; 12/141,134;12/141,141; 12/141,143; and 12/141,146. These applications generallydescribe absorbent core constructions that minimize or eliminate theneed for and inclusion of airfelt or other forms of cellulose fiber incombination with particles of superabsorbent polymer (hereinafter,“substantially airfelt-free cores”). Airfelt and other cellulose fiberhave been used as absorbent fillers in absorbent cores of disposablediapers. Such fiber possesses absorbent properties and imparts someabsorption capacity to an absorbent core, but also is included toprovide a structural matrix to hold dispersed particles ofsuperabsorbent polymer and/or absorbent gelling material. Whileinclusion of such particles enhances absorption capacity, keeping suchparticles suitably dispersed may be important to prevent the particlesfrom “gel-blocking” in use as they swell with absorbed liquid, causingloss of absorption capacity. The inclusion of airfelt or other cellulosefiber as a matrix for superabsorbent particles can serve to reduce orprevent gel-blocking. However, it also imparts bulk to an absorbentcore, even before absorption of any liquids.

In accordance with the disclosures in the co-pending applicationsidentified immediately above, referring to the examples depicted inFIGS. 5C and 5E herein, an absorbent core 71 having a portion that issubstantially airfelt-free may be disposed between the topsheet 51 andthe backsheet 52. The core 71 may include a layer formed at least inpart of a substrate, distributed absorbent particles 66 of asuperabsorbent polymer or absorbent gelling material, and athermoplastic adhesive composition capturing the distributed absorbentparticles 66 and adhering to at least portions of the substrate, therebyimmobilizing the absorbent particles 66 on or proximate to, and relativeto, the substrate.

Features of an outer cover 20 as described herein provide for a wearableabsorbent article that has a relatively improved, garment-like (orunderwear-like) fit, comfort and appearance (as an outer garment orunder other clothes), as compared with many types of wholly disposablediapers currently available. If an outer cover 20 having such attributesis used with an insert 50 having an absorbent core 71 incorporatingsubstantial amounts of airfelt or other cellulose fiber, the improved,garment-like fit, comfort and appearance provided by the outer cover 20may be compromised by the bulkiness of the insert. In order to betterpreserve some or most of the improved, garment-like fit, comfort andappearance of the outer cover 20, therefore, it may be desirable toconstruct absorbent core 71 of insert 50 with features as described inone or more of patent applications cited immediately above, whichprovide for a relatively thin absorbent core.

In addition to providing an absorbent core having reduced bulk, thesubstantially airfelt-free core may generally be more flexible than anabsorbent core containing substantial amounts of airfelt or othercellulose fiber. This enhanced flexibility may enable the core and theassociated insert to better conform about the wearer's body when in use,providing for improved comfort and less bulky appearance of the wearablearticle 10.

Additionally, by reducing or eliminating airfelt or other cellulosicfiber material, the substantially airfelt-free core reduces the amountof materials consumed in manufacturing, reduces the amount of space (andin some circumstances, weight) per unit which must be packaged andshipped, conserving resources in that regard, and reduces the amount ofmaterials and bulk which must be disposed of in connection withdisposing of a used/soiled insert.

Sublayer

Insert 50 may also include a sublayer disposed between topsheet 51 andbacksheet 52. The sublayer may be any material or structure capable ofaccepting, storing or immobilizing bodily exudates. Thus, the sublayermay include a single material or a number of materials operativelyassociated with each other. Further, the sublayer may be integral withanother element of insert 50 or may be one or more separate elementsjoined directly or indirectly with one or more elements of insert 50.Further, the sublayer may include a structure that is separate from thecore 71 or may include or be part of at least a portion of the core 71.

Suitable materials for use as the sublayer may include large cell openfoams, macro-porous compression resistant nonwoven highlofts, large sizeparticulate forms of open and closed cell foams (macro and/ormicroporous), highloft nonwovens, polyolefin, polystyrene, polyurethanefoams or particles, structures comprising a multiplicity of verticallyoriented looped strands of fibers, absorbent core structures describedabove having punched holes or depressions, and the like. One example ofa sublayer includes a mechanical fastening loop landing element, havingan uncompressed thickness of about 1.5 millimeters available as XPL-7124from the 3M Corporation of Minneapolis, Minn. Another example includes a6 denier, crimped and resin-bonded nonwoven highloft having a basisweight of 110 grams per square meter and an uncompressed thickness of7.9 millimeters which is available from the Glit Company of Wrens, Ga.Other suitable absorbent and nonabsorbent sublayers are described inU.S. Pat. Nos. 6,680,422 and 5,941,864. Further, the sublayer, or anyportion thereof, may include or be coated with a lotion or other knownsubstances to add, enhance or change the performance or othercharacteristics of the element.

Standing Cuffs

Insert 50 also may have a pair of longitudinal standing cuffs 53attached partially or entirely along the length thereof. Suitablelongitudinal standing cuffs (in various published examples identified as“leg cuffs”, “barrier cuffs” “gasketing cuffs,” etc., may be formed ofmaterials and construction such as described in, but not limited to,

U.S. Pat. Nos. 6,786,895; 6,420,627; 5,911,713; 5,906,603; 5,769,838;5,624,425; 5,021,051 and 4,597,760; and copending U.S. PublishedApplication No. 2007/0239130 and U.S. application Ser. No. 11/195,272.As shown in FIG. 3, standing cuffs 53 may have one or more strands orstrips of cuff elastics 58 a, 58 b disposed longitudinally therealong.If such cuff elastics 58 a, 58 b are pre-strained prior to being affixedto the web material forming standing cuffs 53, resulting longitudinaltensile forces therealong will cause the web material forming standingcuffs 53 to gather as shown, and cause the cuffs to extend from the bodyof the insert (upwardly relative to FIG. 3), or causing them to “stand”.This feature causes standing cuffs 53 to form a gasketing structurealong the wearer's body when the article including insert 50 is worn,longitudinally on either side of the anatomical features where waste isexuded. Thus, standing cuffs 53 may serve to enhance the exudatecontainment capability of insert 50 and, and as a result, of thewearable absorbent article. As with backsheet 52, standing cuffs 53 maybe formed of a substantially liquid impermeable web so as to contain andisolate liquid exudates from the outer cover, outer clothing andenvironment of the wearer. At the same time, standing cuffs 53 may bevapor permeable to provide for breathability of the insert and thewearable absorbent article, reducing humidity in the areas between theinsert and the wearer's body, and helping reduce the likelihood of skinirritation and/or rashes that may result from over-hydration of theskin.

In another example, the material forming standing cuffs 53 may beintegral with the material forming backsheet 52, such as described in,by way of non-limiting example, copending U.S. Published App. No.2007/0239130. In this particular example, referring to and relative tothe view in FIG. 3, a continuous piece of material may form one standingcuff 53, wrap beneath the insert to form backsheet 52, and wrap up theother side to form the other standing cuff 53. This example of awraparound construction may provide improved liquid containmentcapability to insert 50, by eliminating seams along the outerliquid-containing surfaces that include standing cuffs 53 and backsheet52. Another example of this construction is depicted and described inU.S. Pat. No. 4,808,178.

In some circumstances, however, manufacturing and/or economicconstraints may discourage such construction, or else, it may bedesirable for the materials forming standing cuffs 53 and backsheet 52to have differing properties. For example, in some applications it maynot be deemed necessary for standing cuffs 53 to be substantially liquidimpervious, if they are otherwise formed of a nonwoven web materialcomprising closely situated hydrophobic fibers, which may still tend torepel and contain fluid, but may be generally more breathable thansubstantially liquid impervious laminates including films. In thisevent, improved strength and liquid containment attributes can still beimparted by having the material forming standing cuffs 53 wrap onlypartially beneath the lower longitudinal corners of the insert, andaffixed at seams beneath the insert, rather than at its outermost lowercorners as suggested by FIG. 3. One example of this construction isdepicted and described in U.S. application Ser. No. 11/158,563, and inparticular, FIG. 13 therein and associated descriptive text.

Insert Asymmetry

Referring to FIG. 4, insert 50 will have an insert lateral axis 70 thatequally divides its longitudinal length. Insert 50 may have a structurethat is asymmetric across insert lateral axis 70. For purposes of thisdescription, with used with respect to an insert, “asymmetric” and“asymmetry” mean that features, geometry (e.g., shape), materials and/orconstruction on one side of insert lateral axis 70 differ substantiallyin some respect from those on the other side of insert lateral axis 70.Such asymmetric construction results from having various features ofinsert 50 designed to accommodate the body features and functions of theintended wearer (i.e., body contours, excretory and eliminatoryfunctions) as they differ front-to-rear, to enhancecontainment/absorbency performance, comfort, fit and/or appearance ofthe wearable absorbent article, to economize on use of materials and/orto reduce volume of disposable waste. “Asymmetric” and “asymmetry” donot refer to differences across the insert lateral axis that areattributable to features that may be included on an insert only forpurposes of: purely cosmetic coloration or surface decoration; fasteningto an outer cover (such as fastener components described herein); usergrasping of the insert (such as a grasping structure described herein);as indicia for orienting an insert within an outer cover (such asorientation indicia described herein); or for other purposessubstantially unrelated to the body features and functions of theintended wearer as they differ front-to-rear, to affect performance,comfort, fit and/or physical appearance of the wearable absorbentarticle, to economize on use of materials and/or to reduce volume ofdisposable waste.

As one example, topsheet 51 may one or more have apertures 63therethrough, predominately in the crotch and/or rearward region 55 assuggested in FIG. 4. Apertures 63 can permit liquid or low viscosityfecal material to penetrate topsheet 51 and reach absorbent materials inabsorbent core 71 more rapidly than would occur without such apertures,enhancing liquid feces absorption and containment capability of insert50.

In another example, a feces management feature may be disposed in therear of the article, including one or more pockets, spacers, lowviscosity feces management elements, openings in suspended elasticizedtopsheets, and similar features, for example, as described in copendingU.S. application Ser. No. 11/224,779, 11/786,890 and 11/894,087. Thus,topsheet 51 may comprise one or more larger apertures in the rear regionto provide for unrestricted or comparatively less restricted movement ofsolid or higher viscosity waste therethrough. The size of an aperturemay be important in achieving the desired fecal waste encapsulationperformance. If the aperture is too small, the waste may not passthrough the aperture, either due to poor alignment of the exudationpoint and the aperture location, or due to fecal masses having a sizegreater than the aperture. If the aperture is too large, however, thearea of skin that may be exposed to “rewet” from the contained wastematter is increased. An aperture may have an area of between about 10cm² and about 50 cm². In some circumstances it may be desired that anaperture has an area of between about 15 cm² and 35 cm².

An insert may have asymmetry in its absorbent core (absorbent coreasymmetry). Absorbent core asymmetry may result from arrangement ofmaterials and features within the absorbent core to locate particularmaterials and features of the absorbent core where they are most neededand/or most effective, in accordance with features and functions ofwearer anatomy as they differ front-to-rear.

For example, all or a portion of the rearward region 55 of insert 50 mayinclude acquisition/distribution material 71 but less or no storagematerial 66 as compared with forward region 54, as may be seen bycomparison of FIGS. 5A and 5B, 5C and 5D, and 5E and 5F, respectively.By this particular absorbent core asymmetry, storage material 66 may belocated predominately in the front of the wearable absorbent articlewhen worn. This may provide a predominate proportion of the insert'surine storage capacity closer to the urine exudation point of the wearerto reduce the likelihood of leakage, and remove potentiallyuncomfortable and/or unsightly size and bulk from between the wearer'slegs or the wearer's backside area, particularly relevant when storagematerial 66 becomes swollen with absorbed liquid. Additionally, thisparticular asymmetry provides for economization of the amount of storagematerial 66 used, by locating it in only a portion of the insert ratherthan substantially along the entire insert. The liquid storage capacityof the forward region of the absorbent core may be greater than that ofthe rearward region of the absorbent core as measured by the TeabagCentrifuge Capacity test disclosed in U.S. Pat. No. 6,278,037. Theliquid storage capacity of the forward region of the absorbent core maybe at least about 10%, 20%, 50%, or even 100% or more greater than thatof the rearward region. With such an arrangement,acquisition/distribution material 65 located in both forward andrearward regions 54, 55 can serve to acquire and move liquid (usually,urine) to the storage material 66 located predominately in the forwardregion 54. Alternatively, or additionally, the area and/or basis weightof the acquisition system or component materials in the forward regionof the insert may be at least about 10%, 20%, 50%, or even 100% or moregreater than that of the rearward region. Alternatively, oradditionally, the surface area, cross-sectional area and/or lateralwidth of absorbent core 71 may be greater in the forward region 54 ascompared with the rearward region 55. For example, the surface area,cross-sectional area and/or lateral width of absorbent core 71 may begreater in the forward region 54 as compared with the rearward region55, to accommodate a greater proportion of the acquisition/distributionand/or storage material present in the forward region of the absorbentcore.

Referring to FIGS. 5A, 5C and 5E, in other examples, absorbent material66 in forward region 54 may be, respectively, dispersed withinacquisition/distribution material 65 (FIG. 5A), contained within aseparate liquid permeable structure or envelope 67 in fluidcommunication with acquisition/distribution material 65 (FIG. 5C); ordispersed on, or within an adherent matrix of, retaining material 68,and in fluid communication with acquisition/distribution material 65(FIG. 5E). Conversely, the rearward region 55 may predominately containacquisition/distribution material 65, but less storage material 66 ascompared with forward region 54, or none (FIGS. 5B, 5D, 5F). Materialsin forward region 54 also may be disposed according to constructiondescribed in one or more of co-pending U.S. application Ser. Nos.12/141,122, 12/141,124; 12/141,126; 12/141,128; 12/141,130; 12/141,132;12/141,134; 12/141,141; 12/141,143; and 12/141,146, with a differingconstruction in rearward region 55.

In another example, storage material 66 and acquisition/distributionmaterial 65 may occupying differing, distinct layers of absorbent core71, as suggested by FIG. 5C. It may be desirable in some circumstancesto make the layer containing acquisition/distribution material 65 largerin surface area (i.e., plan view surface area relative to the insertlaid flat, as shown in FIG. 4) than the layer containing storagematerial 66, or vice versa. For example, if the layer containingacquisition/distribution material 65 is formed so as to have a largersurface area laterally across the insert in the forward region 54, thismay serve to provide space for a greater quantity ofacquisition/distribution material in the forward region. This may impartgreater capacity in the forward region to rapidly absorb and distributerelatively large gushes of urine discharged toward the forward region,as may be desired for wearable absorbent articles for, e.g., older malebabies and toddlers—enhancing containment capability of the insert.

In another example, however, such as for newborns and young babies,large gushes of urine might not be expected, but comparativelysubstantial quantities of liquid or low-viscosity fecal material may be.Thus, a wearable absorbent article for this group of intended wearersmay include an acquisition/distribution layer of larger size, occupyinga greater surface area, in the rearward region 55 of the insert. Thismay impart greater capacity in the rearward region to rapidly absorbgushes of liquid or low viscosity fecal material discharged toward therearward region, and thereby enhance containment capability of theinsert.

Differences between forward and rearward regions also may be includedfor purposes of sleep-use inserts. While an insert designed forawake-use may have the predominate proportion of its liquid-storagecapacity in the forward region 54 as described above, an insert designedfor sleep-use with, e.g., young babies, may have the predominateproportion of its liquid-storage capacity in the rearward region 55, toaccommodate babies who sleep lying on their backs, by locating thepredominate proportion of storage capacity where fluid exudates willflow under influence of gravity.

It also may be desired to dispose a thickening agent in the absorbentcore in the rearward region 55 of the insert. A thickening agent may beuseful for providing additional assurance that liquid or low viscosityfecal material will be thickened and thereby more immobilized, and morelikely to be contained within the insert.

Insert 50 also may have overall shape/backsheet asymmetry. For example,viewed in a laid-flat position as shown in FIG. 4, insert 50 may occupya larger surface area on one side of insert lateral axis 70 than on theother. This may be useful for purposes of comfort, body coverage,appearance, performance and/or economization in use of backsheetmaterial(s). For example, in conjunction with including a predominateproportion of storage material 66, the forward region 54 of insert 50may occupy a larger surface area, associated with a larger space withinthe insert to contain the storage material, e.g., an as to improveovernight absorption and containment capacity for wearers who sleep ontheir stomachs, and allow for the insert to remain flatter, particularlyrelevant when the absorbent material becomes swollen with absorbedliquid. Such larger surface area may be greater on one side of insertlateral axis 70 than the surface area occupied by the rearward region 55on the other side of insert lateral axis 70.

Insert 50 also may have a narrowed region in the area which rests in thecrotch region of the outer cover. This narrowing in the crotch regionmay serve to enhance wearer comfort by eliminating size and bulk betweenthe legs. Referring to FIG. 2B, it may also serve to better enable thecrotch region 26 of outer cover 20 to contain and maintain a laterallycentered position of insert 50, by ensuring that insert 50, by havinglimited quantities of absorbent materials therein and limited width,does not swell beyond the space capacity of crotch region 26 of outercover 20. Such narrowing may continue, for example, into the rearportion of the insert, thereby creating overall shape/backsheetasymmetry.

Insert 50 may also be asymmetrical across insert lateral axis 70 inother ways, to serve the same, related or other purposes as thosedescribed above.

It will be appreciated, therefore, that insert asymmetry across insertlateral axis 70 is a result of design and construction of the insert soas to have only one front region and only one rear region, i.e., thefront and rear regions are not interchangeable, if the designed fit,comfort, performance and appearance of insert 50 are to be fullyrealized.

Grasp Structures

Referring to FIGS. 2G-2H, 3 and 4, insert 50 also may include respectiveforward and rearward user grasp structures 59, 61. User grasp structures59, 61 may be provided to enable the user to quickly and easily graspinsert 50 proximate its respective ends.

Grasp structures as shown and/or suggested may enable the user to morequickly grasp and stretch insert 50 from a contracted position similarto that depicted in FIG. 3, to an extended position similar to thatdepicted in FIG. 4, which may be desirable for installing insert 50 intoan outer cover. If user grasp structures 59, 61 are centered proximateto the respective ends of insert 50 as shown, this may also providevisual assistance to the user for co-locating respective centeredfastener component pairs, described in more detail below.

Additionally, user grasp structures 59, 61 may serve to enable the userto quickly and easily grasp insert 50 proximate to its respective ends,which as a result of their distance from exudation points on a wearer'sbody, are less likely to be soiled at the time replacement of insert 50becomes necessary or desirable. Thus, the user may be better enabled toavoid contacting the wearer's exudates with the user's hands whenremoving a soiled insert 50 from an outer cover 20.

Referring to the example depicted in FIGS. 2E-2F, it may be desirable insome circumstances to include more than one grasp structure 59 on theinsert. This may be deemed useful in examples such as depicted in FIGS.2E-2F, where more than one fastener component 56 is disposed on an endof an insert. In such circumstances, including a separate graspstructure 59 associated with and proximate to each fastener component 56may enable a user to manipulate portions of an insert to more easilyaccurately locate and install it within an outer cover with fastenercomponents 59, 33 suitably co-located and/or aligned. It may also enablea user to more easily tug the fastener components 56 away from pairedfastener components 33 to separate them, when it is necessary to removethe insert from the outer cover, by localizing or focusing the user'stugging forces where they are needed to effect such separation.

User grasp structures 59, 61 may include tab-like extensions as shown inFIGS. 2E-2F, 3 and 4, with free ends unattached to the outer cover 20when insert 50 is installed therein, which are easily graspable. Usergrasp structures may have different forms as well. By way ofnon-limiting example, user grasp structures may take the form ofloop-like extensions (not shown) extending from the ends of insert 50,finger holes (not shown) through insert 50 proximate the ends thereof,pockets with openings facing the lateral centerline 70 of the insert,and other structures that facilitate grasping and pulling of insert 50at locations proximate to its ends.

Additionally, grasp structures 59, 61 may be formed of materials havinga high coefficient of friction (e.g., at least about 0.5), resilientlycompressible materials and/or surfaces having three-dimensional relief,to facilitate secure gripping and pulling the insert by the user.

Grasp structures 59, 61 also may be configured or adapted so as can befolded over or under the respective ends of insert, toward the lateralcenterline of the insert. This can serve to conceal the grasp structuresbehind other materials and protect them from contamination by bodilyexudates. Alternatively or in addition, it can serve to add conveniencefor the user.

Insert/Outer Cover Fastener Components; Orientation Indicia; OtherPossible Features

Referring back to FIGS. 2B, 3 and 4, as previously noted, outer cover 20may have one or more insert fastener components such as front and/orrear insert fastener components 33, 32 disposed thereon. Insert 50 mayhave front and/or rear fastener components 56, 57 disposed thereon.Respective front and/or rear fastener components 56, 57 on insert 50 maybe selected and/or adapted to be cooperative to enable fastening withrespective front and/or rear insert fastener components 33, 32 disposedon outer cover 20.

Types, Locations and Localization of Fastening Locations

In one example, to enable fastening of respective front and rearfastener components 56, 57 of insert 50 with respective front and rearinsert fastener components 33, 32 on outer cover 20, respectivefastening pairs 56, 33 and 57, 32 may include cooperating fastenercomponents. An example of a suitable hook-and-loop fastening system is aVELCRO system, a product of Velcro Industries B.V., components of whichare available from Velcro USA, Inc., Manchester. N.H. A hook-and-loopfastening system provides certain advantages. Because the respectivehook and loop components are supplied in sheet or strip form, they maybe cut into suitably shaped patches that can be affixed to a clothsubstrate by various mechanisms, including adhesive bonding, mechanicalbonding, ultrasonic bonding, sewing, stitching, serging, edging, and thelike. If respective hook-and-loop patches are used as fastenercomponents, relative ease of fastening, simplicity and convenience forthe user (as compared with, for example, fastener components such as abutton and button hole) are one among several advantages provided,because fastening is effected simply by placing the fastener componentsin face-to-face contact and applying gentle pressure.

Some types of hook components may, in some circumstances, tend to snagor catch undesirably on a variety of materials in addition to intendedcorresponding loop components, while most types of loop componentscurrently available do not have this tendency. Thus, in somecircumstances it may be desired that patches of loop components form oneor both of insert fastener components 33, 32, while patches of hookcomponents form one or both of fastener components 56, 57. Thisarrangement places a non-snagging insert fastener component on the outercover. This may be desirable in some circumstances, such as when theouter cover 20 is designed to be reusable—reducing the likelihood thatcomponents on an outer cover 20 will undesirably snag on other parts ofouter cover 20 or on other articles, such as clothing articles, beingstored or laundered along with outer cover 20.

However, fastening pairs 56, 33 and 57, 32 need not necessarily includerespective components of a hook-and-loop fastening system, and need notnecessarily include respective components of a two-component fasteningsystem. Rather, a fastening system may require only one fastenercomponent, or use other types of fastener components. Fastenercomponents used may be adapted to engage, retain, and otherwise hold theinsert or a portion thereof. A fastener component on outer cover 20 mayinclude a patch of adhesive; a structure having a region of relativelyhigh coefficient of friction; a pocket; flap; strap; or other capturing,holding and/or retaining surface, device or structure. Thus, referringto FIG. 2C in one example, the inside of outer cover 20 may include oneor more pocket structures 32 a, 33 a situated on or along the innersurface 25 of outer cover 20, in, e.g., the front region 27 or rearregion 28. Such a pocket structure may have an opening facing downwardor upward (relative to the wearer in a standing position, and relativeto FIG. 2B). A pocket structure may be adapted to receive, fit andcapture, for example, the forward edge and a portion of forward region54 of insert 50. A pocket structure 33 a, 33 b may have an openingfacing lateral axis 45, such that an end of insert 50 may be insertedtherein and retained thereby. A pocket structure may alternatively havean opening facing away from lateral axis 45, such that an end of insert50 may be inserted therein and retained thereby, and then insert 50 maybe folded back over such opening and toward lateral axis 45. Referringto FIG. 2D, in another example, one or more pockets 32 b, 33 b may beprovided in the front and/or back region on the inner surface of theouter cover 20 positioned such that a corner of an insert 50 may beinserted into and retained by the pocket. Such pockets may haverespective openings defined by edges of material 32 c, 33 c forming anangle with respect to both the lateral and longitudinal axes of betweenabout 0 and 90 degrees, but more preferably, between about 30 degreesand 60 degrees. One or more of such fastener components may be providedin lieu of, in addition to, or in combination with, other fastenercomponents disposed at the front region of the outer cover 20 andforward region of insert 50. As one example, an outer cover 20 may havea pocket structure 33 a in front region 27 (see FIG. 2C) in combinationwith a patch of loops component forming rear fastener component 32 (seeFIG. 2B). With such a structure and a suitably adapted insert 50 havinga patch of hooks as fastener component 57, to install the insert theuser may insert the forward edge of insert 50 into the pocket structure33 a, and then fasten the rearward portion of insert 50 into the rearregion of the outer cover 20 by engaging respective fastener components32, 57.

In another example, fastener components 32, 33 may be respective patchesof hook components, while fastener components 56, 57 may simply besurfaces formed of woven or nonwoven material adapted to be attachablyengageable by such hook components. In yet another example, fastenercomponents 56, 57 may include respective patches of hook components,while fastener components 32, 33 may simply be surfaces formed of wovenor nonwoven material suitable for, or adapted to be, attachablyengageable by such hook components.

Also, a fastener component in any form, including a respective componentof a fastening pair 56, 33 and 57, 32 may be disposed on either ofinsert 50 or outer cover 20. For example, a hook patch may be disposedon either of insert 50 or outer cover 20, with a cooperating loop patchdisposed on the other of insert 50 or outer cover 20.

An insert fastener component such as component 32 on outer cover 20 maybe attached or connected to at least a portion of an anchoring system,such as an anchoring band 38, or diagonal anchoring band 38 a. This mayprovide, as one advantage, the distribution of structural loadingresulting from the weight of absorbed or contained exudates, asdescribed in one or more of the patent applications cited above, in thedescription of anchoring bands.

Fastening locations may be multiply disposed, for example, at each ofthe four corners of insert 50 and corresponding locations on outer cover20, and even at other locations along insert 50 and outer cover 20,created by fastener components suitably selected and disposed. Forexample, fastener components may be disposed along the longitudinalsides proximate the ends of the insert in the forward and/or rearwardregion of the insert. Fastener components may be disposed adjacent anedge of the insert, or may be disposed laterally and longitudinallyinboard of the edge. For example, a fastener component may be disposedat least 1, 2, or 3 cm from all edges of the insert. In certainembodiments, at least one fastener component is disposed at least adistance from the lateral or longitudinal edge, or both, of the insertequivalent to one-fourth the width of the insert. In one embodiment, afastener component is disposed along at least about one-fifth of thelength of the longitudinal axis.

In another example, a fastening system such as either of fastenercomponent pairs 56, 33 and 57, 32 may form a singularized and localizedfastening location proximate each of, or either, the forward/frontand/or rearward/rear ends/regions as suggested in the Figures. Havingonly two respectively singularized, localized fastening locationssubstantially laterally centered on the insert and the outer cover, assuggested in FIGS. 2B and 3, provides an advantage of simplicity andease of installation for the user, by presenting only two locations atwhich the user must co-locate and fasten insert 50 to outer cover 20.

Additionally, having a single, localized fastening location proximateonly one or two ends of insert 50, such as suggested in FIGS. 2B and 3,provides a partially force-decoupled attachment of insert 50 withinouter cover 20. This may be especially desired in the rear region 28 ofouter cover 20, where extensibility and/or elasticity of outer cover 20may be especially desired to maintain fit, comfort and appearance whileaccommodating body contours and movements of the wearer about thebuttocks and hips. With this force-decoupled arrangement, the portionsof outer cover 20 surrounding fastening element(s) 33, 32, such aswaistband portions 34, 35, and front and rear regions 27, 28, maylaterally stretch and contract substantially independently of andunimpeded by the structure of insert 50 and portions thereof. This mayavoid lateral bunching of the ends of insert 50 with lateral contractionof the outer cover 20, and/or, conversely, may avoid having thestructure of insert 50 restrict outer cover 20 from stretching orcontracting laterally, as a result of a more force-coupled arrangementtherebetween. Such lateral bunching or restricting otherwise may beincidental to fastening insert 50 within outer cover 20 in a manner thatforce-couples a greater portion of the width of insert 50 to outer cover20, e.g. by use of more than one fastening location across the width ofinsert 50 proximate a given longitudinal location, or by use of alaterally delocalized/extended continuous fastening location along alarger portion of the width of insert 50. Force-decoupling, therefore,may provide for enhancement of fit, appearance and wearer comfort, aswell as improved capability for maintenance of intended insert shape andperformance while worn.

Thus, in one example, referring to FIG. 4, a patch of hook componentsforming a fastener component 56 and/or 57 attached to insert 50 may besubstantially laterally centered on the insert as suggested in thefigure, and may have an width W_(f) attached along insert 50 thatextends no more than about 50% of the lateral width W_(i) of the insert50 at forward region 54 and/or rearward region 55. This provides that nomore than about 50% of the width of the insert 50 at, e.g., forwardregion 54 and/or rearward region 55, will be force-coupled to the outercover by operation of the patch of hook components, and that,correspondingly, about 50% of such width (i.e., that portion of widthW_(i) that is not attached to, or force-coupled to, the insert alongwidth W_(f)) is force-decoupled from the outer cover 20 when insert 50is installed therein. In some circumstances, it may be desired that theportion of the lateral width of forward region 54 and/or, especially, ofrearward region 55 of insert 50 that is force-decoupled from the outercover is even greater than about 50%. Thus, it may be desired that thewidth W_(f) of a fastener component 56 or 57, comprising, e.g., acontinuously attached patch of hooks, is no more than about 40%, no morethan about 30%, or even no more than about 20%, of the lateral widthW_(i) of the insert at the region where the fastener component issituated. In another example, it may be desired in some circumstancesthat at least about 50% of the lateral width of the insert 50 in thefront and/or rear region 54, 55, is force-decoupled from the outercover. In some circumstances it may be desired that more than about 50%,more than about 60%, more than about 70%, or even more than about 80%,of the lateral width of the insert at any longitudinal location, isforce-decoupled from the outer cover when installed therein.

As depicted in FIGS. 2E-2F and 2G-2H, examples are contemplated whereinsingularized/localized force-decoupled fastener component pairs 32, 57may be employed in the rear region 28 of the outer cover 20 and rearwardregion 55 of the insert 50, while fastener component pairs 33, 56effectively controlling the forward corners of the insert 50 may beemployed in the front region 27 of the outer cover 20 and forward region54 of the insert 50. This may allow force decoupling of the stretchableouter cover in the back of the article, while maintaining control overthe front corners of the insert.

Other fastener components that provide such singularized and relativelylaterally localized fastening locations, providing limitedforce-coupling across the lateral width of at least one end of insert50, are possible. Other suitable fastener components may include tab andslot fasteners, macro hook and loop fasteners, button fasteners,interlocking fasteners, hook and slot fasteners, snap fasteners andother fastener types available.

In some insert embodiments, as implied above, the corners of the insert50 when in use may be prone to buckling, sagging or rotating toward theinsert lateral axis 70, or out of the contour of the body of the insert,in response to forces resulting from wearer motion or position, orexudate loading, e.g., in the crotch region. Also, referring to FIG. 3,and from the description of standing cuffs 53 with cuff elastics 58 a,58 b set forth above, it can be appreciated that, if longitudinaltensile forces are imparted by pre-strained cuff elastics 58 a, 58 b,standing cuffs 53 may tend to pull the respective outer corners ofinsert 50 longitudinally toward each other. If there is not structurepresent to resist these forces, the outer corners of insert 50 may sagor buckle, and standing cuffs 53 may be loosened, sag or even collapse.This may lead to gaps between the edges 58 of the cuffs and the wearer'sbody. In turn, this may compromise the cuffs' gasketing function, andincrease the risk of leakage.

While it may be important at both ends of the insert, control of theinsert corners may be particularly important in the forward region 54,due to its closer proximity to the urethra. Insert designs in whichexuded urine is predominately stored in the forward region also mayconcentrate the weight and expansion stress of exudate loading in theforward region 56, and thus, on the forward corners of the insert 50.

Control of the corners to reduce the likelihood of such sagging androtation may be improved, in one group of examples, by placement and/orshaping of fastener component pairs. Referring again to FIGS. 2E-2F and2E-2F, it can be seen that fastening component pairs 33, 56 in, e.g.,the respective front/forward regions of the outer cover 20 and insert 50may be arranged, shaped, sized and/or placed such that the forwardcorners of insert 50 are effectively captured and held to the outercover 20 when insert 50 is installed therein. The fastener component(s)56 disposed on the insert may, accordingly, have a width W_(f) at leastequal to about one-fourth, or one-half, of the width of the insert. Insome examples, the width W_(f) of the fastener component(s) may bebetween about 50% and 100%, or between about 75% and 100%, or evenbetween about 85% and 100% of the width W_(i) of the insert (notincluding cuffs 53). If multiple fastener components 56 are included,e.g., in a line, array, or other pattern, the fastener component widthis considered to be the lateral distance between the outermost edges ofthe fastener components 56.

Insert End Support Stiffeners

In some circumstances, inclusion of fastening component pairs whichattach the outer corners of the insert to the outer cover may beundesirable for reasons of cost and/or complexity, or may sacrifice theadvantages of having only one singularized/localized fastening locationproximate each end of insert 50, as described above. Particularly in therear region of the outer cover 28, a singularized and relativelylocalized fastening location providing a force-decoupled arrangement maybe desirable, for the reasons described above.

In this circumstance, it may be desirable to include a stiffeningcomponent proximate to one or both ends of the insert, but especially anend adapted with a singularized and relatively localized fasteninglocation providing a force-decoupled arrangement. Referring to FIGS. 3and 4, end support stiffeners 60 and 62 may be included. Such endsupport stiffeners may serve to aid the user in engaging the insert withthe outer cover, and to help insert 50 maintain its intended shape andconfiguration while being worn beneath an outer cover, i.e., helpmaintain the intended position and gasketing function of the standingcuffs 53. End support stiffeners 60, 62 also may help control thecorners of the insert regardless of the size, type or location offastener components included on the insert. In addition to providingresistance to longitudinal pull of cuff edges 58, end support stiffeners60, 62 may provide resistance to bending in any direction or plane.

End support stiffeners 60, 62 may be affixed to, or incorporated within,insert 50 proximate the ends thereof as suggested by FIGS. 3 and 4. Inaddition to increasing the tendency of insert 50 to maintain optimalshape while in use, such end support stiffeners may increase thetendency of the respective ends of insert 50 to stay open and flatbefore insert 50 is installed in an outer cover. Because the ends ofinsert 50 may otherwise be folded over or bunched while being storedand/or carried by the user before installation, end support stiffenersmay enhance user convenience, by causing the ends of insert 50 tomaintain or seek a shape/configuration that requires less manipulationby the user to install it in an outer cover.

Referring to FIG. 4, one or more end support stiffeners 60, 62 may bedisposed in a lateral orientation with respect to the insert and formedof any flat, sheet-like or card-like material, or any flat, stiffenedassembly. In one example, an end support stiffener may be formed byfolding over a portion of the insert end material(s) to create astiffened region comprising folded layers of material. In anotherexample, end support stiffeners 60, 62 may be formed by depositing ontothe ends of insert 50 lateral bands, strips or other shapes or patternsof deposits of liquid or semi-liquid adhesive or other material thatcures or cools to a stiffened state, and thereby imparts added stiffnessto the substrate to which it is applied. In another example, end supportstiffeners may be formed of cardboard or like material. One example ofsuitable stiffener material is 0.031 in. thick VOLARA foam supplied insheet form (a product of Sekisui Voltek, LLC, Lawrence, Mass.).Stiffener materials may be laminated with or adhesively applied toportions of insert 50 to be stiffened, or applied, affixed or includedby any other suitable method. Other examples of suitable stiffeningmaterials may include added layers of nonwovens, tufted nonwovens,films, laminates of films and nonwovens, patches of fastener loops orhooks components, portions of a suitable grasp structure, etc.

It may be desired that the portions of insert 50 including one or moreend support stiffeners 60, 62 are sufficiently stiff to effectivelyresist the tension forces in standing cuffs 53 and substantiallymaintain standing cuffs 53 in their gasketing configurations whileinsert 50 is in use, and substantially maintain the corners of insert 50in laterally extended positions, preventing buckling or bunching of thesame. The amount of stiffness desired may depend upon various factorsincluding the inherent stiffness of the insert materials without asupplemental end support stiffener, and the amount and/or range oftension in the standing cuffs when the article is worn. At the sametime, for purposes of wearer comfort and safety, it may be desirablethat the portions of the insert including the one or more end supportstiffeners 60, 62 are pliable enough to flex comfortably with thewearer's body movements, and to collapse before any form of contusion orimpalement injury hazard would be presented. It also may be desirablethat stiffened portions are elastic in nature, in they will tend toreturn to a substantially flat configuration after being bent, folded ortwisted.

End support stiffeners 60, 62 may increase planar, lateral and/orlongitudinal stiffness of the areas of insert 50 in which they arelocated, as compared with portions of the insert adjacent suchstiffeners with respect to a plan view (such as FIG. 4). These differingorientational aspects of stiffness may affect various attributes of theinsert. For example, referring to FIG. 3, it can be seen that theability of a portion including an end support stiffener 60, 62(stiffened portion) to resist longitudinal tension forces in standingcuffs 53, may be affected by one or more of planar and longitudinalstiffness of the stiffener. The pliability and relative comfort ordiscomfort for the wearer, associated with a presence of a stiffenedportion, may be affected by planar stiffness of the stiffener.

One measure of stiffness relevant to the ability of a stiffened portionto resist longitudinal tension forces in standing cuffs is EdgeDeflection Force, which is measured according to the Edge DeflectionForce Measurement Method set forth below. In view of the potentiallycompeting objectives of structural rigidity and comfort, it may bedesired that a stiffened portion of an insert end, i.e., the portion ofan end that includes an end support stiffener, have an average EdgeDeflection Force from 0.2 N to 3.0 N, or from 0.4 N to 2.0 N, or evenfrom 0.50 N to 1.70 N, as measured by the Edge Deflection ForceMeasurement Method set forth below.

Another measure of stiffness relevant to the comfort of a stiffenedportion is the Peak Bending Force and Bending Stiffness, which aremeasured according to the Bending Stiffness Measurement Method set forthbelow. In view of concerns for comfort, it may be desired that astiffened portion of a an insert end, i.e., the portion of an end thatincludes an end support stiffener, have an average Peak Bending Force ofno more than 4.0 N, or even no more than 3.7 N, and an average BendingStiffness of no more than 675 N/mm, or even no more than 630 N/mm.

End support stiffeners 60, 62 may be located adjacent or near one orboth ends of insert 50 and may extend laterally from the lateral centerthereof to stiffen the insert along a substantial portion of its width.Alternatively, the stiffeners may be located at least about 0.5, 1, or 2cm from the end of insert 50, and may be substantially centered aboutthe longitudinal center line of the insert. The one or more end supportstiffeners may have a width of from about 50% to about 100% of thelateral width of the insert, or may extend beyond the longitudinal edgesof other materials forming the insert. The end support stiffeners mayhave any longitudinal dimension, although, in some circumstances, alongitudinal dimension less than 25% of the insert length may betterassure comfort for the wearer, and therefore, may be desired. In someexamples, the longitudinal dimension of an end support stiffener mayrange from about 5 mm to about 50 mm. A stiffener also may extendlongitudinally beyond the lateral edge of other materials forming theinsert. One or both ends of the insert may include an end supportstiffener. In examples wherein the insert comprises more than one endsupport stiffener, the respective end support stiffeners may havediffering shapes, dimensions, stiffness, thickness, color, structure,placement, material(s) or composition. An end support stiffener also mayinclude, or be integral with, a grasp structure or fastener component asdescribed above, and as suggested in FIG. 3 (end support stiffener 60 isdepicted as integral with grasp structure 59).

Targeting, Orientation and Alignment Indicia

As discussed above, an insert 50 may be imparted with features that makeit asymmetric about its lateral axis. Despite such asymmetricalconfiguration, as suggested by FIG. 4, insert 50 may have an overallprofile that does not appear to be asymmetric about its lateral axis.For example, as depicted in FIG. 4, insert 50 may have an overallprofile, when opened and laid flat, that is substantially rectangular,and thus, appears to be symmetric about its lateral axis 70. Otherinsert profiles are possible as well, which have overall profiles whichappear symmetric about a lateral axis. Additionally, even where aninsert 50 has an overall profile that is asymmetric about its lateralaxis, it may not be clear just from the profile which portion is theforward portion and which portion is the rearward portion. Thus, absenta sufficiently perceptible signal indicating which portion of the insertis the forward portion and which is the rearward portion, a user mayhave difficulty determining the same, and as a result, may attempt toinstall an insert into an outer cover with incorrect relative front-rearorientation—in turn, resulting in sub-optimal fit, appearance, exudatecontainment and/or comfort.

The insert and/or outer cover may comprise one or more insert targetingindicia to indicate, facilitate and/or compel correct positioning andassociation of portions of the insert within the outer cover. The inserttargeting indicia may comprise verbal or non-verbal instructive indicia,visual targeting indicia, cooperating geometrical features, cooperatingtypes of fastener components, or cooperating designs of fastenercomponents sized and formed to indicate or compel the engagement of theinsert with the correct region of, and in correct orientation with, theouter cover so as to enable the optimum performance of the wearableabsorbent article. Other examples of possible targeting indiciacomponents include one or more cooperating colors, shapes, patterns,lines, outlines, silhouettes, other geometrical features, protrusions ordepressions, textures, patterns, targeting lines or crosshairs,bulls-eye representations, and the like, disposed on the outer coverand/or the insert to indicate correct positioning of the insert withinthe outer cover. In one example, the inner surface of the outer covermay be imprinted with an outline of an insert, or a silhouette of aninsert. Alternatively, one or both of the forward and rearward regions54, 55 of the insert may have disposed thereon a pictogram showing theouter cover shape, or a generalized version thereof, with the front andback of the outer cover indicated via size, color, contrast, or someother indicator, showing the correct insert installation orientation.For example, an outer cover pictogram disposed in the rearward region 55of the insert may have the rear outer cover region, or portions thereof,indicated with a brighter color, an arrow, a circle, etc., while anouter cover pictogram disposed in the forward region 54 of the insertmay have the front outer cover region, or portions thereof, indicatedsimilarly.

Targeting indicia also may comprise at least two cooperating components,one on the outer cover 20 and one on insert 50, such that when these twocomponents are associated, the respective components of outercover/insert system will be properly oriented with respect to oneanother and will perform most optimally. In one example, the innersurface of the outer cover may be imprinted with a first arrow pointingat an insert location, and the insert may be imprinted with a secondarrow pointing at the first arrow when the insert and outer cover arecorrectly relatively positioned.

Indicia may be cognitively correlating, or non-correlating, acorrelation indicating a correct optimal placement, and anon-correlation indicating an incorrect sub-optimal placement.Respective cognitively correlating targeting indicia may include anindicium on the outer cover that cognitively correlates with an indiciumon the insert, indicating to the user the correct relative positioningand engagement of the insert and the outer cover. For example,respective cognitively correlating indicia on the insert and outer covermay have a common color, shape, or texture. (As used herein, “commoncolor” includes any first color and recognizable shades or variantsthereof, which in view of all features of the article is visibly andcognitively distinguishable from another color on the article.)

Referring to FIGS. 2B, 3 and 4, when an insert 50 is asymmetrical asdescribed above, it may have only one optimal forward region 54 and onlyone optimal rearward region 55. Similarly, when an outer cover 20 isasymmetrical as described above, it may have only one optimal frontregion 27 and only one optimal rear region 28. Thus, in the event eitheror both of these asymmetries are substantial, installation of insert 50into outer cover 20 with incorrect relative front-rear orientation maycause the wearable absorbent article not to fit and/or functionoptimally. Accordingly, it may be desirable in some circumstances toincorporate one or more indicia into the outer cover 20 and/or insert 50that are adapted to inform the user as to the correct respectivefront-rear orientation of these components. Such indicia may providesuch information to the user functionally, tactilely and/or visually.

Functional indicia may include fastener components that functionproperly, effectively and/or optimally with correct front-rearorientation, but do not function properly, effectively and/or optimallywith incorrect front-rear orientation.

For example, referring to FIGS. 2B and 3, front insert fastenercomponent 33 on outer cover 20 may be cooperative to effectoptimal/maximum fastening security only with front fastener component 56on insert 50, but not with rear fastener component 57 on insert 50.Similarly, rear insert fastener component 32 on outer cover 20 may becooperative to effect optimal/maximum fastening security only with rearfastener component 57 on insert 50, but not with front fastenercomponent 56 on insert 50.

In a more specific example conceptually appreciated from FIGS. 2K-2L,front insert fastener component 33 on outer cover 20 may include a patchof loops, while front fastener component 56 on insert 50 may include amating patch of hooks (mating relationship indicated by hatching ofcomponents 33, 56 in FIGS. 2K-2L). Correspondingly, rear insert fastenercomponent 32 on outer cover 20 may include a patch of hooks, while rearfastener component 57 on insert 50 may include a mating patch of loops(mating relationship indicated by absence of hatching of components 32,57 in FIGS. 2K-2L). Thus, in this particular example, if a usermistakenly attempts to fasten rear fastener component 57 on insert 50(loops) to front insert fastener component 33 on outer cover 20 (loops),proper or optimal fastening will not be effected, which will communicateto the user that he/she must rotate insert 50 by 180 degrees to installit with correct/optimal front-rear orientation on the outer cover.

In another specific example also conceptually appreciated from FIGS.2K-2L, front insert fastener component 33 on outer cover 20 may includea female snap fastener component, while front fastener component 56 oninsert 50 may include a mating male snap fastener component (matingrelationship indicated by hatching of components 33, 56 in FIGS. 2K-2L).Correspondingly, rear insert fastener component 32 on outer cover 20 mayinclude a male snap fastener component, while rear fastener component 57on insert 50 may include a mating female snap fastener component (matingrelationship indicated by absence of hatching of components 32, 57 inFIGS. 2K-2L). Thus, in this particular example, if a user mistakenlyattempts to fasten rear fastener component 57 on insert 50 (female snapfastener component) to front insert fastener component 33 on outer cover20 (female snap fastener component), the components will not fitproperly together and proper/optimal fastening will not be effected,which will communicate to the user that he/she must rotate insert 50 by180 degrees to install it with correct/optimal front-rear orientation.

Thus, functional indicia may include any fastener components that willfunction properly and/or optimally to effect fastening and maximumfastening security between insert 50 and outer cover 20 when the two areproperly oriented, but will not function properly or optimallyotherwise. Any different types of fastener components or systems may becombined to differentiate the forward and rearward regions of the insertand indicate correct orientation within the outer cover. Generally, withthe use such functional indicia, the fastener components types in theforward region of the insert and front region of the outer cover arerespectively incompatible, or significantly less effective, with therespective fastener components types in the rearward region of theinsert and rear region of the outer cover. As another example of suchfunctional indicia, the front insert fastener pair 33, 56 may be a hookand loop fastening system, while the rear insert fastener pair 32, 57may be a snap fastening system. In another example, the front insertfastening component(s) may include a pocket or flap structure, while therear fastening components embody a dissimilar fastening system. Thefront and rear insert fastening systems may comprise any two differentfastening systems as disclosed herein, or as otherwise available.

In another example, functional indicia may be embodied by fastener pairs33, 56 and 32, 57 having mutually exclusive geometries of similar orcompatible fastening system types. For example, as depicted in FIGS.2E-2F and 2G-2H, the front fastener pair 33, 56 may have a firstplacement and geometry, while the rear fastener pair 32, 57 may have asecond placement and geometry, such that if installation of insert 50within outer cover 20 with incorrect front-rear orientation isattempted, the fastener pairs will not align to provide visibly correctand functionally effective attachment, communicating to the user thatthat he/she must rotate insert 50 by 180 degrees to install it withcorrect/optimal front-rear orientation. In another similar example (notdepicted), the front insert fastening system may have an open circle, ordoughnut-like, geometry, while the rear insert fastening system may havea geometry of a circle with a diameter less than that of the centralopening in the open circle of the front insert fastening system. In yetanother example (not depicted), the front and rear insert fasteningsystems may be located primarily on one side of the longitudinal axis ofthe article (i.e., the longitudinal axes of both the insert and theouter cover). In this example, if the insert is applied to the outercover in the incorrect front-to-back orientation, the insert fasteningcomponents and fastening components will not align correctly. In anotherexample (not depicted), the front insert fastening system may comprisean interlocking fastener oriented along the direction of thelongitudinal axis of the article, while the rear fastening system maycomprise an interlocking fastener oriented along the direction of awaist edge or lateral axis of the article. In another example which maybe conceptually appreciated from FIGS. 2E-2F, the front fastening systemmay include one or more fastening components 33, 56 disposed along thelongitudinal edges of the insert, while the rear fastening system mayinclude a single fastening pair 32, 57 having a width less than theinsert width and disposed on the longitudinal axis of the article.

Functional indicia need not necessarily be limited to fastenercomponents. Functional indicia also may be embodied in other features ofthe outer cover and insert that affect how the two fit or functiontogether in correct, optimal front-rear orientation versus incorrect(reverse), sub-optimal front-rear orientation. Thus, functional indiciamay additionally be associated with or combined with another functionalelement of the outer cover or insert. Indicia may be associated withelements of the outer cover such as a waistband, side panel, stretchelement, leg cuff, physical retention fastener component (e.g., a pocketor retaining strap), and the like. Indicia may be associated withelements of the insert, such as a waist cap, waist band, standing cuff,fecal management feature, insert positioning aid, insert stiffening aid,insert removal aid, or insert disposal aid.

From the foregoing it will be appreciated that other forms of functionalorientation indicia are possible, within the principle of the foregoingdescription. Additionally, any of the differing types of indiciadescribed may be included in a single article, in any combination.

In other possible examples, instead of respective functionallycooperative/uncooperative pairs of components as described above, insert50 and outer cover 20 may include respective non-functional indicia,such as tactile or other sensory indicia.

For example, the front insert and outer cover fastener components may beselected or formed so as to have a first tactile attribute, while therear insert and outer cover components may be selected or formed so asto have a second tactile attribute. In another example, features of theinsert and outer cover may have features such as 3-dimensional shapesthat are mating or geometrically cooperating with optimal front-rearorientation, but not mating or geometrically cooperating with reversed,suboptimal front-rear orientation.

In other possible examples, instead of or in addition to respectivefunctionally cooperative/uncooperative pairs of fastener components ortactile indicia components as described above, insert 50 and outer cover20 may include respective visual indicia. Outer cover 20 may includerespective front and rear visual indicia 73, 74 disposed on the frontregion 27 and rear region 28, respectively. Respective visual indiciadisposed on insert 50 and outer cover 20 may be adapted to provide avisual cue to the user of correct/optimal orientation and placement ofinsert 50 within outer cover 20.

For example, components of visual indicia and a visual cue may involveuse of a common color. In one particular example, front and/or rearvisual indicia 73, 74 disposed on outer cover 20 may comprise respectivecommon colors visibly distinct from one another. (As used herein,“common color” includes any first color and recognizable shades orvariants thereof, which in view of all features of the article isvisibly and cognitively distinguishable from another color on thearticle.) Insert 50 may have respective cooperating indicia disposed orembodied thereon. Thus, for example, forward and rearward user graspstructures 59, 61 on insert 50 may bear or be colored with colorsrespectively common and corresponding with those comprised by frontand/or rear visual indicia 73, 74. More particularly, for example, frontvisual indicium 73 and an insert feature such as forward user graspstructure 59 may both bear or be colored a first common color, and rearvisual indicium 74 and a feature such as rearward user grasp structure61 may either or both be colored a second common color, visiblydistinguishable from the first common color.

In another particular example which may be conceptually appreciated fromFIGS. 2I-2J, 2M-2N and 3, front and rear visual indicia 73, 74 disposedon outer cover 20 may embody, or bear images of respective shapes orsizes to match, or cognitively correlate visually correlate with,corresponding shapes or sizes embodied, or pictured on, insert featuressuch as forward and rearward user grasp structures 59, 61 and/orfastener components 56, 57. More particularly, for example, front visualindicium 73 or forward user grasp structure 59 may both embody or bearimages of triangles, and rear visual indicium 74 or rearward user graspstructure 61 may both embody or bear images of circles. Other examplesof cognitively correlating indicia respectively disposed on an insertand corresponding location on an outer cover include: a baseball andglove, soccer ball and goal, bird and nest, and any other images ofcomponents of well-recognized pairings which would indicate to a userthat two portions bearing or embodying such images are to be broughttogether during installation of insert 50 within outer cover 20.

In another particular example, front and rear visual indicia 73, 74disposed on outer cover 20 may bear images of words or symbolicindications for “front” and “rear”, to match corresponding words orsymbolic indications on insert features such as forward and rearwarduser grasp structures 59, 61. In a more particular example, front visualindicium 73 and forward user grasp structure 59 may both bear an imageof the letter “F” (i.e., for “front”), and rear visual indicium 74 andrearward user grasp structure 61 may both bear an image of the letter“R” (i.e., for “rear”).

In another particular example, front and/or rear visual indicia 73, 74disposed on outer cover 20 may embody, or bear images of, respectiveportions of expectedly user-recognizable shapes, characters, objects,etc., to match corresponding portions of expectedly user-recognizableshapes, characters, objects, etc., embodied, or pictured on, insertfeatures such as forward and/or rearward user grasp structures 59, 61.In a more particular example, front visual indicium 73 and forward usergrasp structure 59 may both embody or bear respective portions of afirst image that, when brought together properly, form a cognitivelycomplete image of an expectedly user-recognizable first shape,character, object, etc.; and/or rear visual indicium 74 and rearwarduser grasp structure 61 may both embody or bear respective portions of asecond image that, when brought together properly, form a cognitivelycomplete image of an expectedly user-recognizable second shape,character, object, etc., distinctive from the first.

In yet another particular example, visual orientation indicia may besimplified into a single pair of visual indicia appearing, respectively,on outer cover 20 and insert 50. In one such example, an inner surface25 of outer cover 20 may bear an image of an arrow pointinglongitudinally toward front edge 21, and insert 50 may bear an image ofan arrow pointing longitudinally toward its forward end.

Examples of other suitable visual orientation indicia adapted to provideorientation information may include alphanumeric text including words,arrows, symbols, diagrams, pictographs, icons, cartoons, schematics, andany other visual indicia.

It may be desired that indicia associated with the front portions of theouter cover and insert will not cognitively correlate, or willcognitively not correlate, with indicia associated with rear portions ofthe outer cover and insert, and vice versa, when the user views bothsets of indicia.

From the foregoing it will be appreciated that other forms of visualorientation indicia are possible, within the principle of the foregoingdescription.

In addition to providing indicia that indicate and/or compel the correctfront-rear orientation of the insert with respect to the outer cover, italso may be desirable to provide indicia that indicate and/or compelcorrect longitudinal and lateral alignment of the insert within theouter cover, in order to provide for the designed optimal containment,fit, comfort and appearance of the article. In the examples shown inFIGS. 2E-2N, respective fastener component pairs 32, 57 and 33, 56 areconfigured and disposed to serve as alignment indicia. It can beappreciated from these examples that fastener components may beconfigured and disposed to not only indicate and/or compel correctfront/rear orientation, but also indicate and/or compel correctlongitudinal and lateral alignment of the insert 50 with respect to theouter cover 20, because co-location of one or both of these fastenercomponent pairs to effect proper fastening will also effect properlongitudinal and lateral alignment. In other examples, separate visualindicia may be included for this purpose, such as, for example,longitudinal alignment indicia 79 a, 79 b and lateral alignment indicia78 a, 78 b disposed respectively on outer cover 20 and insert 50 (FIGS.2E-2F). Referring to FIGS. 2E-2F, it can be seen that insert 50 may belongitudinally and laterally aligned within outer cover 20 by ensuringthat alignment indicia pairs 78 a, 78 b and 79 a, 79 b meet, or areclosely proximate each other, when insert 50 is installed into outercover 20. Visual alignment indicia may take other forms, including, butnot limited to, matching line segments, shapes, insert end or corneroutline images 80 disposed on the inner surfaces of outer cover 20 (see,e.g., FIGS. 2M-2N), etc.

Article of Commerce

It is contemplated that an article of commerce including one or aplurality of outer covers and one or a plurality of inserts, asdescribed herein, may be prepared and sold as such. For example, apackage containing from one to 12, or more, outer covers, together withone or a plurality of associated inserts, may be assembled and soldtogether as packaged. The respective outer cover(s) and inserts in apackage may have matching/complementary fastening systems, orientationindicia and/or alignment indicia as described herein.

For such an article of commerce it may be desirable to determine a ratioof inserts to outer covers suitable to constitute a set of convenientnumbers of outer covers and inserts, respectively. For example, it maybe deemed suitable to include approximately a half day or day's supplyof inserts for each outer cover included in the set. Thus, for example,the article of commerce may include inserts and outer covers in a ratioof inserts to outer covers of 1:1, 2:1, 3:1, 4:1, 5:1 or even 6:1.Accordingly, for example, a package associating a set may include oneouter cover and 1, 2, 3, 4, 5 or 6 inserts; two outer covers and 2, 4,6, 8, 10 or 12 inserts; three outer covers and 3, 6, 9, 12, 15 or 18inserts, and so on. For a “starter” set for certain consumers such asfirst-time purchasers, or in other circumstances, it may be desirablefor a package to contain from 2 to 14 outer covers—which may correspondroughly to from one day's to one week's supply of clean outer coversavailable before laundering becomes necessary.

It may also be desirable to include, in a set including a plurality ofinserts, inserts of differing designs, adapted for use under differingcircumstances. In one example, one or more of the inserts in theplurality may be adapted for extended or nighttime use (sleep-use), andone or more for daytime use, with respect to features such as, e.g.,location of absorbent material and absorbent capacity. Half of thenumber of inserts in the plurality, or fewer than half, may be adaptedfor sleep-use. In one example of this embodiment, the set also mayinclude one or more outer covers decorated with nighttime/sleep themes,such as, for example, images of the moon, stars, nighttime sky colorsand other nighttime scenes, images of sleeping animals, sleeping people,sleeping anthropomorphic characters, etc.; and one or more outer coversdecorated with daytime/play themes, such as, for example, sun, birds,bright colors, daytime sky colors and other daytime scenes, images ofawake/playing animals, people, anthropomorphic characters, etc.

In a further embodiment, a set in a package may be specially adapted foreither boys or girls. For example, a package may include one or moreouter covers having surface decoration and ornamentation associated withlittle girls, e.g., inclusion of pink, lavender and/or other soft pastelcolor schemes, images of flowers, butterflies, bunnies, kittens, littlegirls, princesses, feminine cartoon characters or feminineanthropomorphic characters, etc., or other decorative features generallyassociated with little girls. Conversely, a package may include one ormore outer covers having decoration and ornamentation associated withlittle boys, e.g., inclusion of blue, black, dark or bold color schemes,images of cars, trains, planes, boats, rockets, spaceships, objectsassociated with sports, little boys, masculine cartoon characters ormasculine anthropomorphic characters, etc., or other decorative featuresgenerally associated with little boys. A package designed for eitherboys or girls also may include associated corresponding insertsspecially adapted for either boys or girls, whether by functionalelements or by non-functional, ornamental/decorative elements.Alternatively, a package may contain one or more outer covers andinserts adapted for use with either boys or girls, having gender-neutraldecoration/ornamentation and functional elements.

In a further embodiment, a set in a package may include several types ofinserts, having functional designs that differ in other respects. Forexample, a package may include one or more inserts having one or more ofa feces acceptance aperture in a topsheet, space beneath the topsheetfor isolation of feces, and/or related features such as described in,for example, co-pending U.S. application Ser. Nos. 11/224,779,11/786,890 and 11/894,087.

In a further embodiment, a set in a package may be specially adapted foruse in specific circumstances. For example, a set may include one ormore outer covers and associated inserts adapted for wearing whileswimming or public bathing. In this example, the outer cover(s) andinserts may be adapted for satisfactory use and to substantially retainstructural integrity while soaked and/or immersed in water. For example,the included outer cover(s) may be constructed of materials which do notsubstantially lose tensile strength, stretch or sag when soaked. In thisexample, it may be desirable to form the outer covens) predominately ofpolymeric, hydrophobic materials and/or elasticized textile materials.Similarly, it may be desirable to form included inserts of materialsthat will withstand immersion and soaking without substantial loss ofstructural integrity during the period of intended use. It also may bedesirable to form such inserts without inclusion of superabsorbentpolymer or absorbent gelling material. While these absorbent materialsare often included in the absorbent cores of regular diapers, they maybe deemed unsuitable for use in articles to be worn while swimming orbathing, because such materials would quickly absorb water, and swelland bulge with the absorbed water, upon being immersed—giving up theirabsorptive capacity, adding bulk and weight, and retaining no benefit.Within the same set, however, one or more inserts may be included fornon-swimming, non-bathing use, such that the same outer cover(s) may beused for swimming/bathing and non-swimming, non-bathing activities. Theone or more inserts for non-swimming, non-bathing use may have absorbentcores including superabsorbent polymer or absorbent gelling material.

In a further embodiment, a set in a package may contain a plurality ofdurable outer covers 20, having leg openings defined by leg openingedges 23 that differ in dimension from one durable outer cover toanother durable outer cover. Sequential use of such durable outer coversmay be useful to effect a change in the location(s) at which leg bandportions 36 and leg opening edges 23 encircle and contact the wearer'sskin, each time a durable outer cover in the plurality is replaced byanother durable outer cover in the plurality having such differingdimensions. This may provide the advantage of reducing the likelihood orseverity of chafing of the wearer's skin in the location(s) of suchcontact that may result from the wearer's movements. Such chafing mayotherwise be caused or exacerbated by repeated use of successive durableouter covers having leg openings of substantially unchanging dimensions,which may result in repeated encircling contact with the skin in a moreconcentrated or localized fashion. Thus, for example, a user may apply afirst durable outer cover in the plurality and the wearer may wear itfor a first period of time (such as a day), and the user may apply asecond durable outer cover in the plurality and the wearer may wear itfor a second period of time (such as the ensuing night or followingday), and so on—effectively varying the location(s) on the wearer's skinat which leg opening edges and leg bands encircle and contact it—andreducing the likelihood or severity of chafing. Referring to FIG. 2C, itwill be appreciated that varying any of or any combination of, outercover crotch width WC_(c), outer cover front width WC_(f), outer coverrear width WC_(f), outer cover length LC and leg band length LLB, canhave the effect of varying the size of the leg openings of a durableouter cover 20 when applied to the same wearer. Accordingly, a set of atleast first and second outer cover in a package may have a differencebetween them in any of outer cover crotch width WC_(c), outer coverfront width WC_(f), outer cover rear width WC_(f), outer cover length LCor leg band length LLB, as measured with each outer cover laid outhorizontally on a flat surface, extended to its fullest unstretched(relaxed) dimensions. Any of dimensions WC_(c), WC_(f), WC_(f), LC orLLB may differ between the first and second durable outer covers by atleast about 10%, 15%, 20% or more. In another example, however, thetension forces in leg bands 36 may be varied from one durable outercover to the next, by use of, for example, differing types of elasticstrands or strips, or differing sizes of elastic strands or strips, ordiffering numbers of elastic strands or strips, respectively included byleg band portions 36, or even differing constructions of leg bandportions 36—any of which may effect differences in dimensions of legopening edges 23 from one durable outer cover to another durable outercover within the package.

In a further embodiment, a variety of packages containing a variety oftypes of sets may be presented as a variety of articles of commerce. Inone example, one or more outer covers forming part of a set in a packagemay be seasonal in nature, either by reasons of function ordecorative/ornamental elements or both. Distinctive sets of outer coversmay differ from set to set in attributes such as material basis weight,insulation properties, breathability, etc. For example, a “winter” or“cold weather” outer cover may be formed of materials individually or incombination having a relatively higher basis weight, while a “summer” or“warm weather” outer cover may be formed of relatively lighter materialsand/or materials having greater breathability (as may be characterizedand compared by WVTR).

In another example, one or more outer covers forming part of a set in afirst package may all have decorative/ornamental elements designed by afirst designer and/or be labeled or branded with the first designer'sname or brand, while one or more outer covers forming part of a set in asecond package may all have decorative/ornamental elements designed by asecond designer and/or be labeled or branded with the second designer'sname or brand. In another example, one or more outer covers forming partof a set in a first package may all have decorative/ornamental elementsand/or a label and/or a brand associated with a first particular“collection” or design theme of a designer, while one or more outercovers forming part of a set in a second package may all havedecorative/ornamental elements and/or a label and/or a brand associatedwith a second particular “collection” or design theme of the designer.

In any of the above examples, the outer cover(s) and associatedinsert(s) in each individual article of commerce will be sized to fitoptimally with each other. Thus, in a further example, respectivepackages may be prepared and presented with sets of outer cover(s) andassociated insert(s) distinguished by size. For example, a first packagemay contain outer cover(s) and associated insert(s) adapted for “size 1”children; a second package may contain outer cover(s) and associatedinsert(s) adapted for “size 2” children; and soon.

Edge Deflection Force Measurement Method

Edge Deflection Force is measured on a constant rate of extensiontensile tester with a computer interface (a suitable instrument is theMTS QTest/1 L using Testworks 4.0 software, as available from MTSSystems Corp., Eden Prairie, Minn.) using a load cell for which theforces measured are within 10% to 90% of the limit of the cell.Referring to FIG. 6 a, the movable (upper) pneumatic jaws 1001 arefitted with 1 inch×1 inch diamond-faced grips 1002.

The tensile tester is configured for a compression test. Program thetensile tester to lower the crosshead at a rate of 5.0 mm/min until aforce of 0.01 N is detected. Zero the time and extension channels andbegin data collection at an acquisition rate of 100 Hz. Lower thecrosshead at a rate of 50 mm/min for 10 mm and then return the crossheadto its original gage length. From the force versus extension curve,program the software to report the peak force (N).

Referring to FIGS. 6 a and 6 b, the lower fixture 1000 consists of abase 1005 base 90 mm wide by 40 mm deep by 6 mm thick. The base 1005 isaffixed to a suitable mounting device that includes lower mounting shaft1006, adapted to connect to the stationary mount of the tester. Lowermounting shaft 1006 is threaded as shown and has a locking collar 1007.When the lower mounting shaft 1006 is connected to the stationary mountof the tester, the locking collar 1007 is turned against the stationarymount to immobilize the base 1005 relative the stationary mount of thetester, such that it will remain stationary with the stationary mount,without any interplay therebetween, during testing. Mounted on the base1005 is a V notched block 1003 that is 30 mm wide by 30 mm deep by 30 mmin height which is made of a low friction material such as Teflon.Referring to the perspective FIG. 6 b, the block 1003 is notched fromside to center with a “V” at an angle 1004 of 10 degrees. As mounted onthe base 1005, the block is centered front to back and offset a distance1012 of 32.7 mm from the center axis of the mounting shaft 1006, withthe line defined by the vertex of the “V” notch intersecting the centeraxis of the mounting shaft 1006.

Obtain 10 samples from 10 inserts for testing as follows: Determinewhich of front or rear portions of the inserts are to be tested, andtake all 10 samples from such portions accordingly. Lay the insert on ahorizontal surface, outer/garment-facing surface up. Referring to FIG.7: Visually identify the inside edge 1022 of the stiffened portion 1009of the end (i.e., the portion having end support stiffener 60 or 62). Ifvisually identifying inside edge 1022 is difficult due to the particularconstruction of the insert, inside edge 1022 may be identified byflattening the insert along the region including the subject end, to itsfull longitudinal extent (stretching it out against any contractioncaused by cuff elastics), laying one hand over the insert near the endto hold the insert in the stretched/flattened position, generally in thelocation indicated as 1020, and using the other hand to lift outer endedge 1021 vertically. The insert will tend to fold first along insideedge 1022, since a natural “hinge” location will exist at the juncturebetween the stiffened portion and the adjacent unstiffened portion. Cutthe stiffened portion 1009 away from the insert, along edge 1022.Stiffened portion 1009 will now be the sample to be tested. Do notremove any components such as fastener components, grasp structures,etc. If outer edge 1021 is not inherently readily distinguishable fromthe cut edge by a distinctive feature such as a grasp structure 59, 61,mark outer end edge 1021 for later identification.

All testing is performed in a conditioned room maintained at about 23C±2 C and about 50%±2% relative humidity. Precondition samples at about23 C±2 C and about 50%±2% relative humidity for 2 hours prior totesting.

Referring to FIG. 6 a for directional and positional orientation, locatea sample 1009 in the grips 1002 with inside edge 1022 horizontal andoriented upward, and outer end edge 1021 oriented downward, and in linewith the bottom edges of the grips 1002. Additionally, locate sample1009 in the grips 1002 such that distance 1010 is 30 mm, and distance1011 is 10 mm. Close the grips 1002 so that sample 1009 is grippedsecurely enough so as not to allow it to slip or rotate during testing,but not so tightly as to cause tearing of the sample at the grips duringtesting.

Zero the load cell and the crosshead position. Start the tensiletester's program, and record the data. Report the peak force (EdgeDeflection Force) (N) to ±0.001 N. For each sample, perform the test onboth the left and right sides (see FIG. 7), and record the EdgeDeflection Force for both sides. Test 10 samples. Calculate the averageEdge Deflection Force found of the 10 samples, both sides.

Bending Stiffness Measurement Method

Peak Bending Force and Bending Stiffness are measured using a constantrate of extension tensile tester with computer interface (a suitableinstrument is an MIS Alliance under TestWorks 4 software, as availablefrom MTS Systems Corp., Eden Prairie, Minn.) fitted with a 10 N loadcell. A plunger blade 2100, shown in FIG. 9 (front view) and FIG. 10(side view), is used for the upper movable test fixture. Base supportplatforms 2200, shown in FIG. 8, are used as the lower stationary testfixture. All testing is performed in a conditioned room maintained atabout 23 C±2 C and about 50%±2% relative humidity.

Components of the plunger 2100 are made of a light weight material suchas aluminum to maximize the available load cell capacity. The shaft 2101is machined to fit the tensile tester and has a locking collar 2102 tostabilize the plunger and maintain alignment orthogonal to base supportplatforms 2204. The blade 2103, is 115 mm long 2108 by 65 mm high 2107by 3.25 mm wide 2109, and has a material contact edge with a continuousradius of 1.625 mm. The bracket 2104 is fitted with set screws 2105 thatare used to level the blade and a main set screw 2106 to firmly hold itin place after adjustment.

The bottom fixture 2200 is attached to the tensile tester with the shaft2201 and locking collar 2202. Two movable support platforms 2204 aremounted on a rail 2203. Each test surface 2205 is 85 mm wide 2206 by 115mm long (into plane of drawing) and made of polished stainless steel soas to have a minimal coefficient of friction. Each platform has adigital position monitor 2208 which reads the individual platformpositions, and set screws 2207 to lock their position after adjustment.The two platforms 2204 are square at the gap edge and the plate edgesshould be parallel front to back. The two platforms form a gap 2209 withan adjustable gap width 2210.

Accurately (±0.02 mm) align the plunger blade 2103 so that it isorthogonal to the top surface of the support platforms 2204 and exhibitsno skew relative to their gap edges. Using the position monitors 2208,accurately set the gap 2210 to 25.00±0.02 mm between the two gap edgesof the support platforms 2204, with the plunger blade 2103 accurately(±0.02 mm) centered in the gap. Program the tensile tester for acompression test. Set the gauge length from the bottom of the plungerblade 2103 to the top surface of the support platform 2204 to 15 mm.

Set the crosshead to lower at 500 mm/min for a distance of 25 mm. Setthe data acquisition rate to 200 Hz.

Obtain 10 test samples 1009 as described in the description of the EdgeDeflection Force Measurement Method, above. (Do not remove anycomponents such as fastener components, grasp structures, etc.)Precondition samples at about 23 C±2 C and about 50%±2% relativehumidity for 2 hours prior to testing.

Examine the sample 1009 to be tested for any exposed adhesive anddeactivate any exposed adhesive by applying baby powder to it asnecessary. Place the sample flat onto the surface of the supportplatform 2204 over the gap 2209 with the wearer-facing surface facingupward. Center the sample 1009 across the gap, with edge 1022perpendicular to the gap. Zero the load cell; start the tensile testerand the data acquisition.

Program the software to calculate the maximum peak bending force (N) andStiffness (N/m) from the constructed force (N) verses extension (m)curve. Stiffness is calculated as the slope of the bendingforce/extension curve for the linear region of the curve (see FIG. 11),using a minimum line segment of at least 25% of the total peak bendingforce to calculate the slope.

Report Peak Bending Force to the nearest 0.1 N and the Bending Stiffnessto the Nearest 0.1 N/m, and record the results. Repeat the test andrecord the results for all 10 samples. Calculate the average PeakBending Force and average Bending Stiffness.

A two-piece wearable absorbent article having some or all of thefeatures described herein may provide advantages over both conventionalwholly reusable cloth diapers and conventional wholly disposablediapers. The potential for use of semi-durable materials, and more sodurable materials, to form an outer cover, provides for an outer coverthat may be used more than once, and, depending upon the materialsselected, used and laundered many times. An outer cover having some orall of the features described herein may eliminate the necessity for adisposable outer cover structure, thereby reducing the volume of soiledwaste the user must dispose of as compared with typical disposablediapers. Additionally, because the possibility of a reusable outer coverthat bears most of the structural loading generally imposed upon adisposable diaper is presented, disposable absorbent portions may havemore simplified designs, reducing manufacturing and material costs ascompared with those of disposable diapers. The possibility for making adisposable absorbent insert of non-traditional renewable materials (suchas paper) is presented. At the same time, a disposable absorbent insertand outer cover having some or all of the features described herein mayin many circumstances prevent most or all soiling of the outer cover bythe wearer's exudates, thereby mitigating sanitation and odor problemsassociated with handling and storage, reducing the frequency oflaundering necessary, and reducing the need for laundering resources,efforts and/or expenses, associated with conventional cloth diapers. Adisposable absorbent insert having some or all of the features describedherein also may provide better absorbency and better isolation ofexudates from both the wearer's skin, and the wearer's clothing andenvironment, than conventional cloth diapers.

Use of durable materials for an outer cover also may provide otherincidental benefits, in creating choices in use of materials forimproved and/or more appealing comfort, fit, designs, colors, patterns,etc. as compared with disposable diapers. An outer cover having featuresdescribed herein provides a wide variety of choices for making awearable absorbent article look more attractive and/or more like anarticle of clothing or outerwear. In addition to the foregoingadvantages, the use of an insert having an asymmetric structure togetherwith orientation indicia allows for the design of an insert tailored towearer anatomy and bodily functions as they differ front-to-rear, betterperformance, and increased economy in design, construction and use ofmaterials, while enabling the user to ensure correct front-rearorientation of the insert within the outer cover. Other advantages areapparent from the description above.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross-referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended that the appended claims cover all such changes andmodifications, and that nothing in the foregoing description or thefigures, but rather, only the appended claims, limit the scope of theinvention.

What is claimed is:
 1. A disposable absorbent insert for use with areusable outer cover adapted to be worn about a wearer's lower torso,the insert having a longitudinal length, a central longitudinal axis, aninsert forward region, an insert rearward region, and an insert lateralaxis between the insert forward and rearward regions and equallydividing the longitudinal length, comprising an insert indicium disposedthereon; wherein the insert is asymmetric across the insert lateralaxis, and is adapted to function on and/or fit the wearer optimally withthe insert forward region disposed proximate to a torso front region ofthe wearer's lower torso and the insert rearward region disposedproximate to a torso rear region of the wearer's lower torso; whereinthe insert indicium provides information to a user concerning correctfront-rear orientation of the insert with respect to the reusable outercover or the wearer; wherein the insert is asymmetric about the insertlateral axis by having a different weight of superabsorbent polymer orabsorbent gelling material present across the insert lateral axis;wherein the insert comprises a user grasp structure extending from anend edge of the insert forward region or an end edge of the insertrearward region, wherein the user grasp structure defines an aperturetherein; a first fastener component in the insert forward region and ona first side of the central longitudinal axis; a second fastenercomponent in the insert forward region and on a second side of thecentral longitudinal axis and oppositely disposed about the centrallongitudinal axis with respect to the first fastener component; and athird fastener component in the insert rearward region and intersectingthe central longitudinal axis.
 2. The insert of claim 1 comprising apair of elasticized standing cuffs.
 3. The insert of claim 2 comprisingan end support stiffener in the insert rearward region.
 4. The insert ofclaim 3 comprising a liquid permeable topsheet, a substantially liquidimpervious backsheet, and an absorbent core disposed between thetopsheet and the backsheet.
 5. The insert of claim 4 wherein theabsorbent core comprises a layer comprising distributed particles ofsuperabsorbent polymer or absorbent gelling material captured by athermoplastic adhesive composition.
 6. The insert of claim 4 wherein thebacksheet is formed of a vapor permeable material.
 7. The insert ofclaim 6 wherein the standing cuffs are formed of a vapor permeablematerial.
 8. The insert of claim 1 wherein the insert indicium is visualor tactile.
 9. The insert of claim 1 wherein the insert is asymmetricabout the insert lateral axis by having a difference across the insertlateral axis selected from the group consisting of weight, absorbentcapacity, wearer-facing surface area, lateral width, and combinationsthereof.
 10. A disposable absorbent insert for use with a reusable outercover forming a portion of a diaper and configured to be worn about awearer's lower torso, the insert having a longitudinal length and acentral longitudinal axis, an insert forward region, an insert rearwardregion, and an insert lateral axis between the forward and rearwardregions and equally dividing the longitudinal length, comprising aninsert indicium disposed thereon; wherein the insert is asymmetricacross the insert lateral axis, and is adapted to function on and/or fitthe wearer optimally with the insert forward region disposed proximateto a torso front region of the wearer's lower torso and the insertrearward region disposed proximate to a torso rear region of thewearer's lower torso; wherein the insert indicium provides informationto a user concerning correct front-rear orientation of the insert withrespect to the reusable outer cover or the wearer; wherein the insert isasymmetric about the insert lateral axis by having a different weightacross the insert lateral axis; and a first fastener component in theinsert forward region and on a first side of the central longitudinalaxis; a second fastener component in the insert forward region and on asecond side of the central longitudinal axis and oppositely disposedabout the central longitudinal axis with respect to the first fastenercomponent; and a third fastener component in the insert rearward regionand overlapping the central longitudinal axis.
 11. The insert of claim10 comprising a pair of elasticized standing cuffs.
 12. The insert ofclaim 11 comprising an end support stiffener in the insert rearwardregion.
 13. The insert of claim 12 comprising a liquid permeabletopsheet, a substantially liquid impervious backsheet formed of a vaporpermeable material, and an absorbent core disposed between the topsheetand the backsheet.
 14. The insert of claim 13 wherein the absorbent corecomprises a layer comprising distributed particles of superabsorbentpolymer or absorbent gelling material captured by a thermoplasticadhesive composition.
 15. A disposable absorbent insert for use with areusable outer cover forming a portion of a taped diaper and configuredto be worn about a wearer's lower torso, the insert having alongitudinal length, a central longitudinal axis, an insert forwardregion, an insert rearward region, and an insert lateral axis betweenthe forward and rearward regions and equally dividing the longitudinallength, comprising an insert indicium disposed thereon; wherein theinsert is asymmetric across the insert lateral axis, and is adapted tofunction on and/or fit the wearer optimally with the insert forwardregion disposed proximate to a torso front region of the wearer's lowertorso and the insert rearward region disposed proximate to a torso rearregion of the wearer's lower torso; wherein the insert indicium providesinformation to a user concerning correct front-rear orientation of theinsert with respect to the reusable outer cover or the wearer; whereinthe insert is asymmetric about the insert lateral axis by having adifferent absorbent capacity across the insert lateral axis; wherein theinsert comprises a first user grasp structure extending from an end edgeof the insert forward region and a second user grasp structure in theinsert rearward region, and wherein the first user grasp structurecomprises an aperture as the insert indicium; a first fastener componentin the insert forward region and on a first side of the centrallongitudinal axis; a second fastener component in the insert forwardregion and on a second side of the central longitudinal axis andoppositely disposed about the central longitudinal axis with respect tothe first fastener component; and a third fastener component in theinsert rearward region and intersecting and overlapping the centrallongitudinal axis.
 16. The insert of claim 15, wherein the insertcomprises a liquid permeable topsheet, a substantially liquid imperviousbacksheet formed of a vapor permeable material, and an absorbent coredisposed between the topsheet and the backsheet, and wherein theabsorbent core comprises a layer comprising distributed particles ofsuperabsorbent polymer or absorbent gelling material captured by athermoplastic adhesive composition.